Small format reaction injection molding machines and components for use therein

ABSTRACT

The present disclosure relates to machines and methods for reaction injection molding. In particular, the present disclosure provides small format reaction injection molding machines having exchangeable molds and reactant material tanks, as well as molds configured for use therein and associated componentry.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and the benefit of, U.S.provisional application entitled “Small Format Reaction InjectionMolding Machines and Components for Use Therein” having Ser. No.62/384,237, filed Sep. 7, 2016, which is hereby incorporated byreference in its entirety.

FIELD OF THE INVENTION

The present disclosure relates to machines and methods for reactioninjection molding. In particular, the present disclosure provides smallformat reaction injection molding machines having exchangeable molds andreactant material tanks, as well as molds configured for use therein andassociated componentry.

BACKGROUND

Traditionally, fabrication of plastic parts and pieces has beenexpensive and time intensive due to the need to design and fabricatemolds, as well as the limited accessibility of plastic fabricationequipment to the small scale manufacturer or those seeking to generateprototypes prior to large scale manufacture. In recent years, moldingprocesses have benefited from advancements in computer aided design(“CAD”) and computer aided manufacturing (“CAM”) techniques, which hasreduced costs associated with mold design, as well as reducing the timeneeded to generate high quality molds. Such computerized mold designdoes allow parts to be designed with higher probability that the plasticparts intended for fabrication therein will be both functional and canbe manufactured. However, the parts themselves must still be fabricatedin commercial manufacturing facilities, which require large upfrontinvestment and are typically used as outsourced production resources formany parts and products manufacturers. In order to recoup the cost ofthe production facility, the manufacturer must typically add significantcost to the fabricated plastic part cost, which often can make smallerruns of parts cost prohibitive or, in the alternative, will increase thefinal product in which the fabricated plastic part will be incorporated.Moreover, it is generally not feasible to use such facilities for thefabrication of prototype parts due the cost and uncertainties associatedtherewith.

Additive manufacturing, which may be more commonly known today in thecontext of “3D Printing,” allows plastic parts to be made on a smallscale by melting thermoplastic material and adding it layer by layeraccording to the specifications in a CAD drawing. 3D printing has thebenefit of eliminating the need for mold creation and, accordingly, thismethodology lends itself well to the fabrication of plastic parts on ascale that provides access to a wide variety of users. Indeed, 3Dprinting has substantially transformed the prototyping process in recentyears, making it much easier to generate plastic parts to test theirform and function on a small scale.

3D printing is nonetheless a very time consuming process, and thereforedoes not generally lend itself to use when more than a few pieces orparts are needed. For example, when small format 3D printers are used,it can take one hour or more to make a single part or piece usingconventional processes. While commercial 3D printers are available toprovide faster fabrication, such devices are expensive and, as such, arenot readily available for general use. Thus, users today must trade offspeed for cost and accessibility. This means that widely available 3Dprinters are generally used for rapid prototyping, especially prior toor in conjunction with mold design. Once the prototype configuration isfinalized for manufacture, the CAD information is then used to preparethe mold for manufacture of the piece or part using conventionalinjection molding processes.

The proliferation of 3D printers in recent years, while important toallow the product design and prototyping processes to be substantiallystreamlined, still does not address the need to generate multiplefinished pieces and parts in a short period of time using devices thatare readily available to and more easily deployable by users.

Reaction injection molding is commonly used to fabricate pieces andparts where flexibility, softness and/or pliability is needed. Harder orfoamed parts are also obtainable depending on the reactants used in aprocess. In a reaction injection molding process, two liquidcomponents—“part A”, for example, a formulated polymeric isocyanatecatalyst, and “part B”, for example, a formulated polyol blend, aremixed in a pressurized head and then pumped into a mold cavity. Areaction then occurs in the mold, resulting in a formed polymer part.Since these liquid or liquid-like materials require less pressure thanother plastic fabrication methodologies, they can be injected intocost-efficient aluminum molds, lowering tooling costs. Additionally,such molding processes do not generally require substantial cooling ofthe molds. A further benefit is that the reactant materials can bevaried to allow a myriad of physical properties to be imparted to thefinished part. However, currently, reaction injection moldingmanufacturing processes are conducted on an industrial/commercial scalewith catalyst and reactant stored in large storage tanks and dispensedby large, high-pressure industrial pumps.

The overall cost and complexity of existing reaction injection moldingprocesses means that pieces and parts must generally be sent off-sitefor fabrication after the prototyping phase is complete, thus increasingthe time and cost of part and piece fabrication. In short,notwithstanding the benefits of reaction injection molding processes ingenerating plastic parts for use in many products, this methodology isgenerally not accessible outside of commercial manufacturing facilities.

Moreover, commercial production of plastic pieces and parts oftenrequire only fairly small runs of from 1 to about 5000 pieces. Whenexisting fabrication processes are used (i.e., mold fabrication followedby use of industrial scale plastic production facilities), runs of sucha small size are expensive given the large purchase and operationalcosts associated with commercial reaction injection molding processes.Such background costs will necessarily cause the cost and manufacturingcomplexity of the final product that incorporates the piece or part tooften be greatly magnified. Further, in many processes, manufacturingagility is needed. Early stage product production prior to moving tolarge scale production often requires evaluation of minor changes to theproduct to test various aspects of the product both in manufacturing andin use. Typically, the tooling costs associated with evaluating a minorvariation in part and/or mold design has been an impediment to thosemaking smaller run and/or lower cost molded products.

The movement toward “mass customization” in the marketplace alsodemonstrates a need for manufacturing agility. Runs of medical devicesmay need to be varied by size (e.g, small, medium or large) orcustomization of a lot of products for a particular patient may berequired. Using traditional reaction injection molding processes, suchflexibility is typically too expensive for all but the most expensiveand/or highest volume products.

There remains a need for greater accessibility of users to reactioninjection molding processes for fabrication of pieces and parts for useas finished products or as components in another product, especiallywhere small production runs are contemplated. Moreover, there remains aneed for users to be able to switch out reactant materials and molds ona smaller scale to allow flexibility in the ability to make pieces andparts having varied properties.

SUMMARY

The present invention relates to machines and methods for reactioninjection molding. In particular, the present invention provides smallformat reaction injection molding machines having exchangeable molds andreactant material tanks, as well as molds configured for use therein andassociated componentry.

In one aspect, among others, a reaction injection molding machine cancomprise a housing comprising an interior portion and exterior portion;at least one reactant materials tank engagement station in operationalengagement with a first reactant material tank comprising part A of aninjection molding process and a second reactant material tank comprisingpart B of the injection molding process, wherein the first and secondreactant materials tanks are each, independently, configured tosealingly engage with a corresponding engagement port in operationalcommunication with the at least one reactant materials tank engagementstation, thereby providing a first reactant material fluid stream and asecond reactant material fluid stream, wherein each of the first andsecond reactant materials tanks are configured to hold up to about threegallons each of reactant material, and wherein the first and secondreactant material tanks are sized to fit substantially within at leastsome of the housing of the reaction injection molding machine; a moldingsupport framework comprising a first mold support plate and a secondmold support plate, wherein: (i) the first and second mold supportplates are in respective operational engagement with first and secondmold engagement plates; and the first mold engagement plate isconfigured to securably engage with a first mold part, and (ii) thesecond mold engagement plate is configured to securably engage with asecond mold part to provide an assembled mold suitable for injectionmolding when the first and second mold parts are sealingly engaged; aninjection molding manifold in operational engagement with each of thefirst and second reactant material fluid streams; and an injectionmolding nozzle engagement station configurable for operationalengagement of a proximal end of a mixing nozzle with the injectionmolding manifold and a distal end of the mixing nozzle with theassembled mold.

In one or more aspects, the reaction injection molding machine can beconfigured to apply a pressure to the assembled mold during theinjection molding process that does not exceed about 500 psi. The firstand second reactant materials tanks can each, independently, comprise areactant material to generate at least one thermoset plastic article orpart from the injection molding process. In various aspects, thereaction injection molding machine can comprise a spring releaseassembly configured to apply force to the first mold engagement plateopposite the first mold part. The applied force can facilitatedisengagement of the distal end of the mixing nozzle from the assembledmold. The spring release assembly can comprise a plurality of springsoperationally engaged with the first mold engagement plate and the firstmold support plate. The mixing nozzle can extend through the first moldengagement plate and the first mold support plate for operationalengagement of the distal end of the mixing nozzle with the assembledmold.

In one or more aspects, the molding support framework can be configuredto move the second mold engagement plate to clamp the second mold partagainst the first mold part, thereby forming the assembled mold. Themolding support framework can comprise a linear drive system configuredto move the second mold engagement plate to clamp the second mold partagainst the first mold part. The linear drive system can comprise aplurality of motor driven lead screws supported between the first andsecond mold support plates, the plurality of lead screws in threadedengagement with the second mold engagement plate. In various aspects,the at least one reactant materials tank engagement station can comprisea pump configured to provide at least the first reactant material fluidstream to the injection molding manifold. At least one mold part of thefirst and second mold parts can incorporate a mold identification thatis transmittable to an identification signal receiver associated withthe reaction injection molding machine. The mold identification cancomprise a radio-frequency identification (RFID) tag incorporated intothe at least one mold part, the RFID tag configured to transmit anidentification signal associated with the mold identification for the atleast one mold part.

In one or more aspects, the first and second reactant material tanks canincorporate tank identifications that are transmittable to anidentification signal receiver associated with the reaction injectionmolding machine. The tank identifications can comprise radio-frequencyidentification (RFID) tags incorporated into the first and secondreactant material tanks. The RFID tags can be configured to transmit anidentification signal associated with the tank identification, the tankidentification corresponding to the reactant material in that reactantmaterial tank. Provision of the first reactant material fluid stream andthe second reactant material fluid stream can be restricted until thetank identifications have been verified by the reaction injectionmolding machine. In various aspects, the corresponding engagement portscan comprise a check valve configured to provide a substantially leakproof seal between the first or second reactant materials tank engagedwith that engagement port and the at least one reactant materials tankengagement station. A spring loaded latch mechanism can securely engagethe first or second reactant materials tank with the correspondingengagement port.

In one or more aspects, the first and second reactant material tanks cancomprise a fill level indicator configured to provide an indication ofreactant material in that reactant material tank. The fill levelindicator can comprise a magnetic float incorporated into that reactantmaterial tank. In various aspects, the part A can be a catalyst materialand the part B can be a polyurethane reactant material or a coreactivesilicon or epoxy material. The catalyst material can be a formulatedpolymeric isocyanate catalyst and the polyurethane reactant material canbe a formulated polyol blend. In some aspects, the first and second moldparts can be generated using a 3D printing process. The at least onereactant materials tank engagement station can comprise a key-way foreach corresponding engagement port. The key-way can comprise featuresconfigured to align with corresponding features of either the first orsecond reactant materials tank containing the appropriate first orsecond reactant material for that engagement port.

Other systems, methods, features, and advantages of the presentdisclosure will be or become apparent to one with skill in the art uponexamination of the following drawings and detailed description. It isintended that all such additional systems, methods, features, andadvantages be included within this description, be within the scope ofthe present disclosure, and be protected by the accompanying claims. Inaddition, all optional and preferred features and modifications of thedescribed embodiments are usable in all aspects of the disclosure taughtherein. Furthermore, the individual features of the dependent claims, aswell as all optional and preferred features and modifications of thedescribed embodiments are combinable and interchangeable with oneanother.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the present disclosure can be better understood withreference to the following drawings. The components in the drawings arenot necessarily to scale, emphasis instead being placed upon clearlyillustrating the principles of the present disclosure. Moreover, in thedrawings, like reference numerals designate corresponding partsthroughout the several views.

FIGS. 1 through 3 provide various perspective views of an example of areaction injection molding machine, in accordance with various aspectsof the present disclosure.

FIGS. 4 through 7 provide various views of examples of componentry ofthe reaction injection molding machine of FIGS. 1-3, in accordance withvarious aspects of the present disclosure.

FIGS. 8A through 8D are graphical representations illustrating anexample of the operation of the reaction injection molding machine ofFIGS. 1-7, in accordance with various aspects of the present disclosure.

FIG. 9 is a schematic block diagram illustrating an example of controlor processing circuitry of the reaction injection molding machine ofFIGS. 1-7, in accordance with various aspects of the present disclosure.

FIG. 10 is a flow diagram illustrating an example of the operation ofthe reaction injection molding machine of FIGS. 1-7, in accordance withvarious aspects of the present disclosure.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof, and within which areshown by way of illustration certain embodiments by which the subjectmatter of this disclosure may be practiced. It is to be understood thatother embodiments may be utilized and structural changes may be madewithout departing from the scope of the disclosure. In other words,illustrative embodiments and aspects are described below. But it will ofcourse be appreciated that in the development of any such actualembodiment, numerous implementation-specific decisions must be made toachieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it will be appreciated that suchdevelopment effort might be complex and time-consuming, but wouldnevertheless be a routine undertaking for those of ordinary skill in theart having the benefit of this disclosure.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as is commonly understood by one of ordinary skillin the art to which this disclosure belongs. In the event that there isa plurality of definitions for a term herein, those in this sectionprevail unless stated otherwise.

Where ever the phrases “for example,” “such as,” “including” and thelike are used herein, the phrase “and without limitation” is understoodto follow unless explicitly stated otherwise.

The terms “comprising” and “including” and “involving” (and similarly“comprises” and “includes” and “involves”) are used interchangeably andmean the same thing. Specifically, each of the terms is definedconsistent with the common patent law definition of “comprising” and istherefore interpreted to be an open term meaning “at least thefollowing” and is also interpreted not to exclude additional features,limitations, aspects, etc.

The term “about” is meant to account for variations due to experimentalerror. All measurements or numbers are implicitly understood to bemodified by the word about, even if the measurement or number is notexplicitly modified by the word about.

The term “substantially” (or alternatively “effectively”) is meant topermit deviations from the descriptive term that do not negativelyimpact the intended purpose. Descriptive terms are implicitly understoodto be modified by the word substantially, even if the term is notexplicitly modified by the word “substantially.”

As used herein, “reaction injection molding” is a process in which tworeactive liquid components are metered, blended together, and injectedinto a closed mold at a low or substantially low pressure. As would berecognized, the reaction injection molding process works by combiningtwo liquid components that chemically react in a closed mold to form athermoset plastic part.

Unlike thermoplastic injection processes that require very hightemperatures and pressures to melt and force plastic into a steel tool,reaction injection molding requires significantly less energy andminimal injection force. Instead, under suitable conditions, the liquidsundergo an exothermic, or heat generating, chemical reaction andpolymerize inside the mold to form a cross-linked polymeric structure.Articles or parts comprised of thermoset materials are not meltable uponheating at a level that would cause thermoplastic materials to beginflowing; instead, they will degrade.

“Thermosetting resins” are prepolymers in a solid soft or viscous liquidstate that changes irreversibly into an infusible, insoluble polymernetwork by curing. Thermosetting resins used in the machines and methodsherein are those that comprise at least a “part A” and a “part B” suchthat when combined in the reaction injection molding machines hereinwill undergo curing in an assembled mold to generate a and article orpart.

Accordingly, the articles or parts fabricated using the systems andmethods of the present disclosure comprise thermoset materials. Yetfurther, the articles or parts fabricated using the systems and methodsof the present disclosure consist essentially of thermoset materials.Still further, the articles or parts fabricated from the systems andmethods of the present disclosure substantially do not comprisethermoplastic materials.

Reactant materials suitable for use in the reaction injection moldingmachine of the present disclosure, as well for use to prepare thedisclosed reactant material tanks, can comprise a polyurethane catalyst(e.g, an isocyanate) and a polyurethane reactant material (e.g., apolyol), as well as other suitable materials as discussed hereinafter.Polyols used in the present disclosure can be polyether polyols, whichare made by the reaction of epoxides with an active hydrogen containingcompounds. Polyester polyols used in the present disclosure can begenerally prepared by the polycondensation of multifunctional carboxylicacids and polyhydroxyl compounds, as discussed further herein.Additional materials that can be used in the reaction injection moldingmachine and the reactant material tanks of the present disclosure caninclude epoxy and/or silicone reactants, as discussed further herein.

By convention, the catalyst aspect of the reactant materials is “partA,” and the polymeric reactant material/polyol/epoxy aspect is “part B.”That convention will be followed in the disclosure herein.

“Small format” is used herein to mean a reaction injection moldingmachine that is configured to fit on a benchtop, a desktop, acountertop, a tabletop or the like. In this regard, the reactioninjection molding machine can have dimensions of up to about 80 inchesin length by 36 inches in width by 48 inches in height, or in the rangeof about 36 inches in length by 20 inches in width and about 24 inchesin height. When the reaction injection molding machine includes reactantmaterial tanks suitably engaged within the machine (as discussedelsewhere herein), the reaction injection molding machine is configuredto incorporate a total of from about 4 to about 12 gallons of reactantmaterials, where such materials are loaded from a plurality of tanks asset out elsewhere herein.

In this regard, the reaction injection molding machine is configured toincorporate at least two reactant material tanks—that is a firstreactant material tank and a second reactant material tank—wherein eachof the tanks, independently, are charged with reactant materialsappropriate to fabricate the part in need of fabricating. In someaspects, the reaction injection molding machine can incorporate at leasttwo or more reactant material tanks, with the specific reactant materialarrangement in the machine being variable, and in association with theconfiguration of the reactant materials engagement station as discussedherein.

As would be recognized, the reaction injection molding machine can beconfigured with suitable operational components (e.g., pumps, hosingetc.) to allow incorporation of the auxiliary materials. Additionally,control or processing circuitry associated with the reaction injectionmolding machine can allow management of auxiliary material addition.

A wide variety of part sizes can be fabricated in a reaction injectionmolding machine of the present disclosure, where the part size isdetermined substantially by the mold configuration used in each moldingoperation. In some aspects, the disclosed molding technology can be usedto generate parts having dimensions of up to about 16 inches by 16inches by about 7 inches. Parts can be fabricated in a wide variety ofsizes below the largest part size for which the reaction injectionmolding machine is configurable. As would be recognized, the part sizeis generally defined by the size of the molds used in the reactioninjection molding machine. In this regard, parts as small as 0.10 inchby 0.10 inch by 0.05 inch can be fabricated therein.

Reaction injection molding machines of the present disclosure aresuitable for the fabrication of production runs that would otherwisegenerally not be cost effective to generate in standard injectionmolding operations. To this end, the disclosed technology is suitablefor use to fabricate from about 25 to about 25000 pieces or parts in asingle run. Yet further, the presented technology is suitable for thefabrication of from about 25, 50, 100, 500, 1000, 2500 or 5000 or morepieces or parts, where any value can form an upper or a lower endpoint,as appropriate.

Shot size, that is the volume of parts A and B used in a reactioninjection molding process, can vary widely within the parameters of thesmall format machine of the present disclosure. The shot size for use inthe reaction injection molding machines of the present disclosure canrange from about 0.1 ounce to about 1 gallon. The shot size willinfluence the number of parts that can be made from each fully chargereactant materials tank, as would be recognized, with smaller partsallowing more parts to be made between tank changes and vice versa. Inthis regard, the fabricated part may be at the high end of the sizerange of the machine (e.g., 16×16×7 inches) and have a thin wall, or maybe a small part (e.g., 0.1×0.1×0.1 inches) can incorporate a relativelylarge volume of material used to fabricate each part, such as when thepart is substantially solid.

When the reaction parts A and B used in the reaction injection moldingmachine are a catalyst and a polyol, respectively, a wide variety ofurethane components can be used as the polyol in the preparation offabricated parts from the reaction injection molding machine and in thetanks configured with the reactant materials for use in the disclosedreaction injection molding machine. Broadly, both elastomeric and/orflexible polyols and their associated suitable urethane catalysts can beutilized, wherein the fabricated part can comprise a substantially rigidhigh modulus impact-resistant material down to a substantially softand/or flexible rubber-like material. Yet further, the fabricated partcan comprise a substantially rigid material having a flexural modulusand hardness comparable to that of a glass-like material.

The reaction injection molding machine can be configured to providefabricated parts that comprise solid polyurethane, for example, partsthat comprise substantially homogeneous flexible or rigid plastic.

Still further the reaction injection molding machine can be configuredto provide fabricated parts that are foamed polyurethane and, as such,the reactant material tanks can incorporate such polyols and theirassociated suitable catalysts. As would be recognized, foamedpolyurethanes comprise blowing agents to form a sandwich of high-densityrugged skin and a lower density cellular core, or the material can be“self-skinning” in which the fabricated part will form a durable skinupon polymerization. The system rigidity and cell size can be varied toprovide suitable properties as required for the fabricated part. In thisaspect, the molds used in the disclosed technology can be vented toimpart air flow into the mold, and an associated blowing or vacuumapparatus can be incorporated in an interior of the reaction injectionmolding machine housing. The venting allows air inside the mold cavityto escape when the mold is filled with resin. If the air could not ventout of the cavity, then the trapped air can create bubbles or voids inthe parts. The vents can be very thin channels (e.g., 0.001″ deep) goingfrom the cavity to the outside world, and can be machined into theparting line of the molding parts. For example, the vent can be an openchannel that, when the molds come together, allows air to leave throughthis channel at the parting line of the assembled mold).

Reactant materials tanks comprising the polyol can comprise a singletype of polyol material to be supplied to the mold along with a suitableisocyanate. Yet further, properties of the finished parts can be variedby blending various polyols in a single reactant material—that is, thepolyol containing reactant material tank—where that polyol blend is fedto the mold along with the suitable catalyst material. Alternatively, aplurality of polyol-containing reactant material tanks and/or auxiliarymaterials tanks can be engaged with the reaction injection moldingmachine as discussed further herein, and various amounts of eachdifferent polyol can be fed to the mold along with associated suitablecatalysts as directed by the control or processing circuitry thatprovide the part fabrication instructions. Similarly, when reactivesilicones or epoxies are used with the associated catalysts, differentreactant tanks can be incorporated into the reaction injection moldingmachine so as to vary the final properties of the fabricated part.

Yet further, reactive silicones can be used in conjunction withassociated catalyst materials. In this regard, part A can comprise acatalyst material, and part B can comprise the coreactive siliconematerial. When incorporated into the mold, the mixture of parts A and Bwill generate a thermoset reaction.

Epoxy materials and their associated catalysts can also be used tofabricate parts in the reaction injection molding machine of the presentdisclosure, as well as stored in the reactant material tanks configuredfor use in the machines herein. In this regard, the epoxy-type catalystscan comprise polyfunctional amines, acids (and acid anhydrides),phenols, alcohols and thiols. As would be recognized, epoxy reactantmaterials are low molecular weight prepolymers or higher molecularweight polymers which normally contain at least two epoxide groups.

The reaction injection molding machine of the present disclosure isconfigurable to allow fabrication of a wide variety of parts and pieces.In not limiting examples, the small format reaction injection moldingmachine can be used to fabricate medical device products, industrialparts (e.g., caster wheels, body panels, housings, mechanicalcomponents, consumer goods, electronics housings, etc.).

In yet further aspects, the reaction injection molding machine can beconfigurable to provide composite systems that can provide fabricatedparts that are foam or solid, rigid or elastomeric, but that alsoinclude fiber reinforcements, such as glass or other reinforcing fibers,to enhance the structural properties of the molded part. Stiffness andimpact strength can be enhanced by adding reinforcement in the materialstream (e.g., reinforced reaction injection molding—R reaction injectionmolding) or by using a molded preform in the mold that is encapsulated(e.g., structural reaction injection molding—S reaction injectionmolding).

Additionally, the reaction injection molding machine can be configurablefor one or more additional ports or inputs, where such additional portsor inputs are for auxiliary materials, such as accelerators (to decreasereaction time), UV hardeners (to increase resistance to UV light),and/or colorants (for custom color blending). These one or moreadditional ports or inputs can be incorporated within the reactioninjection molding machine housing, for example, in the engagementstation (as described hereinafter), whereby the reaction injectionmolding machine can further incorporate a fluid stream configured todeliver that auxiliary material to the mixing nozzle along with the partA and part B components. For example, auxiliary material tanks can beengaged with ports inside the reaction injection molding machine.Alternatively, the reaction injection molding machine can be configuredto allow engagement of external tanks or containers that can allow theauxiliary materials to be added for delivery to the mixing nozzle asappropriate in a particular molding operation. For example, one or moreexternal tanks comprising auxiliary materials can be operably engageablewith the reaction injection molding machine through input connections orother fluid communication aspects to allow incorporation thereof into amolding operation.

The reaction injection molding machine of the present disclosurecomprises a housing, wherein the housing comprises an interior portionand an exterior portion. Access is enabled into the interior of thehousing via a door. These and other aspects of the disclosed technologyare described in more detail hereinafter. The housing can be fabricatedfrom a plastic material or a composite material, metal (e.g., steel,aluminum), fiberglass (e.g., fiberglass reinforced plastic or FRP), orsuch as pressed wood board (e.g., medium-density fiberboard or MDF). Insome aspects, the housing can be constructed from two differentmaterials, for example, the housing can be partially comprised ofplastic and metal. Yet further, the housing material can be comprised oftwo types of plastic, etc. For example, the door to the housing cancomprise a translucent plastic material that allows visibility into theinterior of the reaction injection molding machine, whereas a balance ofthe housing can be comprised of a plastic that is opaque. Yet further,the various aspects of the housing can be comprised of differentmaterials as appropriate to impart physical strength as needed. Forexample, the housing door can be comprised of a plastic materialappropriate to impart flexibility to enable the door to be opened andclosed easily but where structural support is not typically needed,whereas a balance of the housing can be comprised of a plastic that hasgreater rigidity so as to impart more structural support to the reactioninjection molding machine as a whole. Moreover, the reaction injectionmolding machine housing can be reinforced with a plurality of ribs orthe like. For aesthetic purposes, such reinforcement is beneficiallyincorporated on the interior of the housing. Still further, the cornersand any edges of the reaction injection molding machine can be chamferedto impart additional strength to the housing, for example.

On an interior of the housing, molding support components are securabletherein. In some aspects, the molding support components are operablyengagable with a plurality of lead screws and stepper motors, where suchlead screws and stepper motors are configurable to provide engagement ofthe individual mold parts to provide a mold suitable for use ininjection molding to generate the desired fabricated part.Alternatively, the molding support components can be operably engagedwith one or more hydraulic pistons, electric linear actuators or otherlinear movement devices to provide engagement of the mold parts so as toallow the respective mold parts to engage to provide a mold suitable forinjection molding as described herein.

In some aspects, all or part of the molding support components areremovably engageable with the interior of the reaction injection moldingmachine, such as by way of screws, pins, clamps or the like. Suchremovable engagement can allow replacement of the molding supportcomponents due to wear and breakage. Modularity of parts in this regardcan also facilitate repair of the reaction injection molding machine bya user.

As noted, the configuration and size of the fabricated parts made in thereaction injection molding machine of the present disclosure can besubstantially determined by the design of the molds generated for use inthe disclosed reaction injection molding machines. Any mold type that isusable for reaction injection molding in larger format machines can bemodified for use herein, as long as it is configurable to be engageablyremoveable (or removably engaged) with the reaction injection moldingmachine as discussed herein. The molds suitable for use in the disclosedtechnology can comprise spray metal molds, steel molds, aluminum molds,plastic molds, kirksite molds, composite molds comprising use ofmultiple materials (for example, a plastic base with aluminum insertcavities), silicone or soft rubber molds, or zinc molds. In someapplications, spray metal molds can be used to enhance control ofsurface quality and can offer improved moldability. Aluminum or steelcan be used when increased physical properties of a urethane materialsystem are indicated, or longer mold life is needed. Aluminum or steelcan be used when increased physical properties of a urethane materialsystem are indicated, or longer mold life is needed. The reactioninjection molding machine of the present disclosure allows a widevariety of mold components to be used, thereby providing a highlymodular and flexible machine design and functionality. Moreover, theease with which the molds may be exchanged by a user expands the usecases for injection molding. In some applications, spray metal molds canbe used to enhance control of surface quality and can offer improvedmoldability.

In accordance with various aspects of the present disclosure, moldssuitable for use in the reaction injection molding machines of thepresent disclosure can be fabricated from CAD or other computerizedmodels, as is known. A mold maker can generate reaction injectionmolding machine molds for use in the disclosed technology according toknown methods from such renderings. The renderings can be uploaded intothe cloud for offsite mold generation and fabrication and shipped to thelocation where the reaction injection molding will be conducted, as alsois known. In an exemplary example, a mold fabricator can provide a 3DCAD model and design a mold from that model using techniques generallyknown in the art, such as computer numerical control (CNC) machining andelectro discharge machining (EDM) techniques to generate the mold,generally in two pieces. When assembled, each mold can comprise at leasta cavity side and a core side, which can also be referred to herein as“first mold part” and “second mold part,” where the specific identity ofeach as either the core or cavity side is determinable from the contextin which the terms are used. In some cases, the molds can furthercomprise inserts, slides or other suitable componentry to allow complexshapes and undercuts to be created in the finished parts where suchwould not readily be achievable through a simple cavity/core molddesign.

Lower weight molds are easier for users to switch out componentry, andcan reduce wear and tear on the reaction injection molding machine. Tomaintain the weight of the mold as low, for example so as to facilitatein the ease of changing out the mold from the machine, the molds used inthe reaction injection molding machine can comprise “hybrid” molds. Suchhybrid molds utilize various material combinations to provide anappropriate ratio between needed durability of the mold and weight. Forexample, a mold suitable for use in the reaction injection moldingmachine of the present disclosure can utilize plastic componentry, suchas POM (Polyoxymethylene (Acetal)) or ABS (Poly(Acrylonitrile ButadieneStyrene)), to machine a frame structure for the mold and utilizealuminum to create the cavity and core inserts for the mold. Thealuminum cavity and core inserts would then be intimately attached tothe frame in such a way that the mold comprises a monolithic structurehaving a light weight, plastic frame, with a durable aluminum insert. Inthis regard, the aluminum insert can provide durability and longevitythroughout a series molding cycles of the mold and the plastic frameprovides a lighter weight mold overall.

Molds suitable for use in the molding technology disclosed herein can befabricated by, e.g., casting liquid resin (silicone, epoxy, urethane,etc.) around a 3D rendering of a part that can be replicated by aninjection molding operation. The part to mold could be derived from a 3Dprinted part, a CNC part or a previously injected molded part. Forgeneration of the mold, the part can be secured in a frame and liquidresin can be injected around the secured part in such a way to fill theentire space around the part. Upon hardening, the mold is opened along adesired parting line and the part can be removed from the mold. The moldwould then have an internal cavity space representing the part. Thismold would then be ready to use in the disclosed reaction injectionmolding machine.

A further method for mold making could comprise the use of 3D printers,where a 3D printer can fabricate the mold from a 3D CAD file designed bya mold maker. The use of 3D printers to make molds can provide forrapid, low cost solutions to making molds. Additionally, the machinecould have a 3D printer built in to the internal workings of the machinein such a way as to print a mold and then immediately begin injectingresin in to the mold cavity. This method could facilitate an automatedprocess from mold making through injection molding whereas the mold,printed by a 3D printer inside the machine, was integrated into thereaction injection molding process whereby the molds can be generated inreal time as opposed to offsite at another factory or on anothermachine.

Using 3D printers, molds for use in the reaction injection moldingmachines and processes of the present disclosure can be generated inreal-time or substantially real time. The low pressures utilized in thereaction injection molding processes of the present disclosure can beutilized to make polymeric molds suitable for use in the disclosedmolding technology. Since the reaction injection molding machines of thepresent disclosure are generally intended for production runs ofrelatively low volumes, the lower wear tolerance usually associated withpolymeric runs is of lesser concern, especially in view of the lowpressures and temperatures used in the reaction injection moldingprocesses herein. Moreover, even if the parts wear out, the on-demandavailability of molds generated by 3D printing can allow such parts tobe generated quickly. Rapid prototyping can be greatly enhanced by thecombination of 3D mold printing with the reaction injection moldingmachines and methods of the present disclosure. 3D printed molds alsoallow verification of injection mold designs before investing inexpensive metal molds.

When 3D printed polymeric molds are used, 3D printing processes suitableto produce parts to a high accuracy and having excellent surface finishcan be desirable. To this end, stereolithography (SLA) 3D printers canproduce completely solid, smooth parts that can withstand thetemperature and pressure of the reaction injection molding processesherein. 3D prints produced by SLA are chemically bonded such that theyare fully dense and isotropic, producing functional molds suitable foruse herein. As would be recognized, stereolithography uses UV lasersdirected via dynamic mirrors onto a bed of liquid plastic to curepatterns, cross-section by cross-section.

Additive inkjet printing can also be used to generate polymeric molds,for example with PolyJet™ printing. PolyJet™ and related additive inkjetprinting (referred to collectively as “PolyJet” for convenience) usesmultiple print heads to deposit liquid plastic onto a clean buildplatform layer by layer. The material is cured as it is deposited.PolyJet can deposit material in layers as fine as 16 microns.

SLA and PolyJet both require support material to ensure accuracy, anchorparts to the build platform and aid the creation of delicate,overhanging features. SLA supports are created out of the same materialas the final part and must be sanded and removed by hand. SLA parts arenot built fully cured in order to drain out excess resin, and therefore(aside from support removal) they require additional curing in a UVoven. PolyJet parts are built fully cured. PolyJet supports are createdout of a separate material specially formulated to release from thefinal part with water blasting and some hand labor. Both methods canproduce suitably smooth molds; PolyJet parts offer a smoother surfaceright off the build, stereolithography parts generally are sandableafter curing is complete.

To generate a two part 3D printed mold for use in the reaction injectionmolding machines and methods of the present disclosure, a CAD design ofthe desired part is provided using known methods. 3D printed mold designis similar to techniques used to generate metal molds. Once the part isdesigned, the mold design is then created in 2 parts. As would be known,the mold design can take into account the design and operationalparameters associated with reaction injection molding processes. To thisend, some minor design modifications may be beneficial when usingpolymeric molds vs. metallic molds, but such modifications are readilyachievable by one of ordinary skill in the art. Each mold part is thenprinted using a suitable 3D printing device, followed by removal of thesupport structure from each part, as would be known. Post-curing isgenerally desirable to ensure appropriate hardness of the mold parts,but materials choice and time between mold creation and use in thereaction injection molding machine will generally dictate whether suchpost-curing is indicated. If sanding/smoothing of the interior portionsof the mold parts is desirable, this can be conducted. Once thepolymeric mold parts are ready for use, the parts are secured in themachine for use, in accordance with the description set out in thisapplication. The molding process can then be started, also as set out indetail herein.

In one aspect, the 3D printer can be in operational engagement with thereaction injection molding machine. The 3D printed mold can then beautomatically generated and automatically inserted into the reactioninjection molding machine so as to allow little to no human supervision.Once generated, the molded parts can be automatically ejected asdescribed elsewhere herein. When new parts are to be generated, new moldparts can be generated in accordance with stored mold designs.

3D printing in metal is emerging as a methodology, and is expected to bea viable mold-making technique in the future. As such, the technologydisclosed herein can be used with such “additive metal manufacturing.”Metals available for 3D printing include Stainless Steel 17-4PH,Stainless Steel 316L, Aluminum (AlSi10Mg), Inconel 625, Inconel 718,Titanium (Ti64) and Cobalt Chrome (CoCrMo)5. In general, these materialsexhibit weld-ability and strength comparable to conventionally builtmetals. Higher tensile strength materials include INCONEL 625 andCoCrMo. Ti64 is a biocompatible material; parts 3D printed with thismaterial meet ASTM F1372 requirements for gas distribution systemcomponents. The process to generate 3D printed metallic mold partsgenerally follow the steps described above with regard to generating 3Dprinted polymeric parts. Design modifications appropriate for generatingand using such metallic mold parts can be determined by one of ordinaryskill in the art with trial and error.

Metal 3D printing begins with metals provided in powder form. Thepowdered metal materials are heated and fused by a laser using thatenergy to weld the mold designs from CAD representations layer by layerby addition of metal powder to the previously formed layers. In onenon-limiting example, a roller in a 3D printer spreads out a very finelayer of metal, such as aluminum in powder form. A laser then sintersand solidifies the areas that are part of the design as defined by a CADfile. A subsequent layer of powder is then provided, such as by rollingand then sintering the rolled powder as defined by the design featuresfor the mold. Such powder application continues layer by layer until thedesired mold design is completed.

Ejector pins and other methods of part ejection from the mold may beindicated in a molding process molding process. In some aspects, themolded parts are ejectable from the mold assembly by way of ejector pinsin operational engagement with the machine. Yet further, springs inoperational engagement with the machine are configurable to provideejection of the fabricated part from the mold assembly.

The molds fabricated for use in the disclosed molding technology areappropriately engageable with the reaction injection molding machine ofthe present disclosure. In this regard, each of the molds comprises afirst mold part and a second mold part that are each configured toconnectably engage to provide an assembled mold suitable for use in aninjection molding operation with the reaction injection molding machineof the present disclosure. Each of the first and second mold parts aresecurably engagable with a corresponding first and second moldengagement plate, for example, via a plurality of complementary moldpart alignment pins or other type of fasteners disposed on each of thefirst mold part and first engagement plate and the second mold part andsecond engagement plate. Each of the mold first and second mold partscan be securable to the first and second mold engagement plates,respectively, via a plurality of mold alignment screws that areconfigured to align with corresponding engagements on the respectivemold parts. In various aspects, each of the mold engagement plates andcorresponding mold parts fabricated for use in the reaction injectionmolding machine of the current disclosure comprise complementarycomponents to allow slidable, threadable or other types of securableengagement.

The mold part engagement plates are each, independently securable to theinterior of the reaction injection molding machine. The mold partengagement plates can be securably engaged with mold support plates,each of which are on an exterior side of the respective mold engagementplates. The mold support plates can be removably secured to the interiorof the housing, such as by screws or the like.

In some aspects, the mold part engagement plates can be engageabletoward each other within the reaction injection molding machine via atleast two lead screws disposed on a top side and a bottom side of eachof the engagement plates. The lead screws are securably engaged to themold support plates, for example. Each of the mold part engagementplates can slidably engage with the lead screws via connections asdiscussed further herein. The movement of the mold part engagementplates can be facilitated by at least two guide rails disposed proximateto the top lead screw and the bottom guide rail, or through the use ofguide rails on the bottom, side or top of the mold engagement plates.Other supporting features such as guide pins can also be included.

One or both of the mold engagement plates can move to bring therespective mold parts together, to generate an assembled mold. In someaspects, only one plate will move, and the other plate will staystationary. The latter can be beneficial to allow molds of varying sizesto be suitably attached in the reaction injection molding machine duringuse. In this regard, the first mold part and the second mold part can besized to fit on corresponding fasteners, for example bolts, that arepermanently fixed in the reaction injection molding machine inassociation with the mold engagement plates. The mold engagement platescan, in turn, be sized with bolts or other fasteners that areappropriately sized for the specific mold being used in a particularfabrication effort. Larger molds can present more and/or differentlyspaced fasteners (e.g., bolts) than may be needed with a smaller mold.The mold engagement plates can be provided in a plurality of sizes,wherein such differently sized engagement plates are removablyattachable to the interior of the reaction injection molding machine.The user can exchange the mold engagement plates as appropriate to matchthe alignment pins with a first and second mold part to be used in thereaction injection molding process.

In some aspects, the assembled mold is configured to make a single partin each molding operation, that is, with each injection of material in asingle mixing operation and with a single mixing nozzle use. Stillfurther, the assembled mold is configured to make multiple parts of thesame design in each molding operation, that is, with each injection ofmaterial in a single mixing operation and with a single mixing nozzleuse. Yet further, the assembled mold is a “family mold” configured tomake multiple parts of different designs in each molding operation, witheach injection of material in a single mixing operation and with asingle mixing nozzle use, where a “family mold is a kind of multi-cavitymold where each cavity produces different parts of the same product. Theparts produced by the different cavities may also be unrelated, they canbelong to the same product line or to the same project.

The assembled mold can incorporate a mixing nozzle insertion pointdisposed into an interior of therein, wherein the mixing nozzleinsertion port is configured to allow insertion of at least a portion ofa distal end of the mixing nozzle. The mixing nozzle can be secured atthe mixing nozzle engagement point, which can be located proximal to themixing nozzle insertion port. As discussed further hereinafter, when themixing nozzle is in fluid communication with each of the reactantmaterials needed for the reaction injection molding processes, the mixedreactants can be introduced into the interior of the assembled mold soas to fabricate a part in the reaction injection molding machine herein.In one aspect, a distal end of a mixing nozzle is insertable through afirst mold part secured to a first mold engagement plate, where thefirst mold part is engaged with a second mold part secured to a secondmold engagement plate to provide an assembled mold.

The reaction injection molding machine of the present disclosure isconfigurable to validate that each of the mold parts are appropriate foruse in the reaction injection molding machine. When the mold part(s) arevalidated, the reaction injection molding machine can be configured toproceed with a molding operation. Either or both of the mold parts canincorporate a mold identification tag or code that is transmittable to amold identification signal receiver associated with the reactioninjection molding machine. Such tagging or identification code can beprovided by RFID, bar code scanning, direct connection circuit (e.g.,wires directly connected between the machine and a small chip on themold), physical marks, and active systems where communications (e.g.,Wifi, Bluetooth, etc.) are natively embedded on one or more of the moldparts so that each tank incorporates communications functionality. Insome aspects, the mold identification code can allow identification ofmolds that are authorized for use in the reaction injection moldingmachine of the presentation disclosure. To this end, an authorizationcode may be generated to be incorporated into the control or processingcircuitry associated with the reaction injection molding machine.

To ensure that molds used in the disclosed technology are appropriatelygenerated to ensure that quality parts and pieces can be fabricated fromthe reaction injection molding machine of the present disclosure, themachine can be configured to lockout or otherwise disable unauthorizedmolds from being operational therein. As would be recognized,unauthorized (that is, counterfeit or the like) molds may not beconfigured to the necessary quality specifications needed for the piecesand parts being fabricated in the reaction injection molding machines ofthe present disclosure. Such quality specifications may be important forsome or even substantially all of the uses in which the pieces and partsare intended for use, and molds that cannot be assured to conform tosuch requirements should not be useable in the reaction injectionmolding machines in the present disclosure. Such molding qualityspecifications can include cycle time, molding pressure, clampingpressure and molding temperature, among other parameters.

Improperly fabricated molds, such as those made using inferiortechniques, can result in the fabricated parts being of low quality.Moreover, such improperly fabricated molds can be subject to prematurefailure, such as breakage during use, where such breakage can result indamage to the reaction injection molding machine. The control orprocessing circuitry associated with the reaction injection moldingmachine is therefore configurable to identify the mold parts via a moldidentification code that is transmittable to a mold identificationsignal receiver associated with the reaction injection molding machineas authorized for use in the machine. If the unique identifier providedby the mold part(s) (or if the unique identifier is missing) indicatesthat the mold part(s) are not authorized, the control or processingcircuitry associated with the reaction injection molding machine isconfigurable to lockout the mold from use, such as by deactivating thereaction injection molding machine until the mold-machine mismatch iscorrected. The control or processing circuitry optionally includes anoverride that can allow the reaction injection molding machine tooperate without the authorization code or other mold validation code.This override can be controlled through a remotely located server (e.g.,by the machine supplier), which is in communication with the reactioninjection molding machine through a network or other communicationslink. The parameters of the reaction injection molding machine can beupdated or modified by the machine supplier to, for example, overrideexisting molds and materials constraints.

Yet further, the reaction injection molding machine can be configured toperform one or more quality checks to ensure that the molds retain theability to generate pieces and parts of suitable quality specifications.In this regard, prior to becoming operational for the first or in asubsequent operation or during extended operation, the reactioninjection molding machine can perform one or more mold quality checksthat may include, in non-limiting examples, determination of moldingpressure, cycle times, clamping pressure, and reactant materialtemperature, where such information is obtained from a plurality ofsensors in operational communication with the reaction injection moldingmachine. The acquired sensor data can be compared with baseline valuesthat are incorporated in the control or processing circuitry associatedwith the reaction injection molding machine. Should one or more aspectsof the quality check show that the reaction injection molding machine orits attendant operational parameters are out of compliance with one ormore specifications, the machine can be configured to lockout orotherwise be disabled from operation. In some aspects, the user can beprovided with a notice and instructions on how to bring the reactioninjection molding machine or its components into compliance so thatoperation can be reinstituted.

In some aspects, molding quality checks can be facilitated in use byoptional incorporation of a camera into the interior of the reactioninjection molding machine, whereby images can periodically be generatedduring operation of a molding process. Such images can be provided forviewing to a technician located near the site of the reaction injectionmolding process or remotely who can confirm that the operation of thereaction injection molding machine, and any molds incorporated therein,are suitably operational in a specific process. If it is determined thatthe machine and/or any molds are not suitably operational, theinstructions can be provided to lockout operation of the reactioninjection molding machine to allow suitable repairs or adjustments to bemade. The technician can make adjustments to the machine operationremotely, if appropriate.

The reaction injection molding machine of the present disclosure canoptionally include cooling functionality that can be introducedproximate to the injection molding station. As would be recognized, suchcooling can facilitate curing, thereby allowing cycle time to bedecreased, with a corresponding increase in the number of parts that canbe fabricated per unit time. Such cooling can be provided by a fandisposed proximate to the injection molding station, although otherforms of fan placement and cooling are contemplated. However, generally,a substantial benefit of the reaction injection molding machines andprocesses of the present disclosure include relatively minimal heatgeneration using most resin selections. Fans may also be desirable todissipate fumes from the interior of and proximal to the reactioninjection molding machines. Any fans incorporated in our around thereaction injection molding machines can be configured with a NIOSHfilter to reduce the fumes associated with the injection moldingprocess.

Still further, the control or processing circuitry associated with thereaction injection molding machine can be configured to measure thevarious operational parameters of the reaction injection molding machineduring use and confirm that the device is suitably operational therein.If one or more operational parameters are not in compliance, where suchcompliance is provided by defined specifications associated with aparticular molding operation that are incorporated in the control orprocessing circuitry associated therewith, the reaction injectionmolding machine can be instructed to stop part fabrication so as toenable adjustment or maintenance. Alternatively, if out of complianceoperation is found, the reaction injection molding machine can beconfigured to slow down the speed of part fabrication as needed to bringthe operation into compliance.

Another aspect of the disclosed technology comprises the configurationof the reactant materials utilized with the reaction injection moldingmachine of the present disclosure. In this regard, each of the reactantmaterials, that is, the part A and part B (as well as any auxiliarymaterials, if present), can be incorporated into removable raw materialreactant tanks specifically configured for use in the reaction injectionmolding machine. In some aspects, the reactant materials can beincorporated in tanks that are removeably configured to each,independently, be sealably engageable with associated engagement portsin an engagement station. In some aspects, the removable engagement isfacilitated, in part, by a check valve on the reactant materials tankwhere the reactant materials tank is configured to sealably engage witha corresponding engagement port that is, in turn, configured with fluidcommunication components associated with the reaction injection moldingmachine.

In some aspects, the engagement ports can be configured with checkvalves. The engagement ports can also each, independently, be configuredwith a check valve. The engagement port check valves are configurable toprovide a substantially leak proof seal between an associated reactantmaterials tank and each of the engagement stations and, therefore, thecorresponding fluid communication channels. In this regard, theinterior, that is, any fluid communication associated with the reactioninjection molding machine can be substantially sealed when a reactantmaterials tank is not engaged in a port. When a reactant materials tankis engaged with a port, the check valve in the port and the check valvein the tank can then allow raw material to flow from the tank into themachine. The sealable engagement between the reactant materials tank andthe corresponding fluid communication components can also comprise afriction fit, a gasket seal fit, a spring latch lock, or a screw-typefit, with the fit appropriately providing the ability to obtain asubstantially leak-proof connection between the reactant materials tankand the fluid communication components.

The reactant materials engagement stations can be fabricated from anymaterial in which the componentry can be incorporated therein. Theengagement stations are intended to be suitably durable to last forextended uses. Accordingly, the engagement stations can be comprised ofstainless steel or aluminum, or other suitably durable materials.

The fluid communication componentry in operational engagement with theone or more reactant materials engagement stations can comprise tubingor hoses that are fabricated from (or lined with) material that issubstantially chemically impervious—that is, unreactive with orinsoluble in—the reactant materials used in the reaction injectionmolding processes and that can withstand the associated pressures of themolding operation, for example about 10 to about 500 psi.

Still further, the pressures applied in the molding processes of thepresent disclosure substantially do not exceed about 500 psi. It hasbeen found that the ability to conduct molding operations under suchrelatively low applied molding pressures enables a variety of part sizesto be fabricated using the systems and methods herein. In this regard,thermoplastic injection molding requires high pressures to ensure thatthe melted resin can adequately fill all portions of the mold so as toavoid short shots, especially when fabricating small parts and/or partshaving fine details. As would be recognized, a “short shot” is theincomplete filling of a mold cavity that results in the production of anincomplete part. This happens when the flow of the thermoplastic resinfreezes off before all of the flow paths in the mold have been filled.In such prior art thermoplastic resin injection molding processes, thehigh pressures needed to ensure adequate resin flow also requires largerequipment footprints in order to accommodate the pressure generationequipment (e.g., air compressors) that can provide the necessarypressure required for complete resin flow through the mold. Accordingly,the use of thermosetting resins herein, which require pressures of lessthan about 500 psi, enables a heretofore unavailable equipmentfootprint.

The reactant materials engagement ports in the reaction injectionmolding machine allow the reactant materials tank to be sealinglymounted into the interior of the reaction injection molding machine soas to facilitate generation of the compact footprint of the machine ofthe present disclosure. The plurality of reactant materials tanks aresubstantially situated within the interior bottom footprint of thereaction injection molding machine, where the bottom footprint comprisesthe maximum area defined by the width and length of the machine asmeasured proximate to the lower portion of the machine.

Yet further, the mouth area of the reactant materials tank can besecurely engaged with the reaction injection molding machine during use.Such secure engagement can be provided, for example, by a spring loadedlatch mechanism configured to keep the tank intimately engaged in acheck valve assembly/configuration. When this spring loaded latch ismanually released, the reactant materials tank (or resin tank) canseparate from the engagement port and the check valve assembly canreturn to a closed state, thus substantially sealing the tank contentsfrom ambient conditions. While the check valve can substantially preventthe reactant material from leaking from the tank, a screw-top or otherseal can also be removably associated with the mouth of each reactantmaterials tank, for example, to ready the reactant materials tank forlong term storage.

Each reactant materials tank can incorporate a pressure regulating checkvalve to maintain the internal air pressure substantially regulated asthe reactant materials are removed from the tank during moldingoperations. Such a pressure regulating check value can be set tomaintain the air at any level of vacuum applied to the tank during use.It has been found that the air inside a tank should be regulated toreduce the possibility that air entrapment inside of the reactantmaterials (or resin) tank might cause bubbles to be formed in afabricated part. When the reactant materials tanks are filled, a smallvacuum (e.g., about 5 psi below ambient air pressure) can be drawn oneach tank. A small pressure regulating check valve can be incorporatedinto the top of each tank (e.g., opposite the mouth area) to maintain aconstant vacuum in the reactant materials tank. As the reactant material(e.g., part A or part B) leaves the tank, the pressure regulating checkvalve can let a small amount of air into the tank to maintain thepressure level. The air allows the reactive material to continue toleave the tank while minimizing the amount of new air (and humidity)that enters the reactant materials tank.

Yet further, the water vapor present in the air that is in contact withthe resin should be minimized. In particular, water vapor can damage theproperties of resins and/or catalysts and can affect shelf life of thematerials in the tanks. Desiccants and other water absorbing materialscan therefore be optionally incorporated into or proximal to either orboth of the reactant material tanks.

The respective reactant material tanks can be designed for specificcomplementary fit in the engagement in the corresponding port. Forexample, the first reactant materials tank can be configured to fit onlyin the reactant materials port associated with that tank. The secondreactant materials can be configured to not fit in that the firstreactant materials tank port or slot, so that the user does notaccidently engage the reactant materials tank comprising part A to theport where the reactant materials tank comprising part B should beengaged, and vice versa. Yet further, the first reactant materials tankis configured to suitably engage only with the first engagement port,and the second reactant materials tank is configured to suitably engageonly with the second engagement port.

Removal and insertion of the respective reactant materials tanks can befacilitated by a lockable engagement, such as by a latching mechanism.For example, when a user engages a reactant materials tank in anassociated raw materials port, a latch can be engageable to secure thetank in the port. Upon removal of the tank, the user can release thelatch to allow the tank to be removed from the port within which it isengaged. The latch can “unlock” the engagement and, in some aspects, canprovide a disengagement force that can assist in dislodging the tankfrom the engagement port. In some aspects, the replacement of tanks canbe facilitated by the incorporation of a rotatable or slidable aspect inthe reaction injection molding machine. For example, a plurality oftanks can be removably engaged on a rotatable or hinged component.

The control or processing circuitry associated with the reactioninjection molding machine can also be configured to notify the operatorof a mismatch between the appropriate port engagements. In this regard,one or a plurality of reactant tank ports (or part A tank port or ports)on the reaction injection molding machine can be specifically configuredto mate with a reactant materials tank configured to contain part A andone or a plurality of tank ports (or part B tank port or ports) can bespecifically configured to mate with a reactant materials tankconfigured to contain part B. For example, the reactant materials tankports can include key-ways that match with corresponding reactantmaterials tanks. The key-ways can comprise one or more open or coveredslots (or grooves) located on one or both sides of the tank ports thatallow the one or more keys (e.g., tabs or protrusions) on one or moresides of the reactant materials tanks to slide into during installationof the corresponding reactant materials tank. If a user attempts to matea part A reactant materials tank with a part B tank port, the reactioninjection molding machine can be configurable to lockout or disable themachine from operation and to provide information to the user that theorientation of the ports needs to be corrected.

Yet further, the reaction injection molding machine can be configurableto confirm to a user that the reactant material tanks are engaged in thecorrect port. In this regard, each reactant materials tank can comprisea unique identifier that is readable by the reaction injection moldingmachine, and the correct placement thereof can be confirmed. Detectionof a suitable reactant materials tank is in the appropriate port can befacilitated by mechanical switches, a bar code reader, infrareddetectors, RFID or the like. For example, each reactant materials tankcan include at least one of a RFID tag, optical recognition, physicalsensing, etc. If no reactant materials tank is detected in an associatedengagement port that is configured for engagement with the particularport, or the reaction injection molding machine control or processingcircuitry detects that a reactant materials tank engaged with the portis spent, or that a reactant materials tank was not fabricated by anauthorized source or refilled by an unauthorized party, reactioninjection molding machine can prompt the user to insert a new ordifferent reactant materials tank. Moreover, the reaction injectionmolding machine can include lockouts that prevent the reaction injectionmolding machine from operating unless the operator completes thedirected operations related to the reactant materials tank(s). Once thetank/port mismatch is corrected, the reaction injection molding machinecan then again be made operational.

While each of the reaction injection molding machines of the presentdisclosure can be configured to incorporate reactant materials tankshaving each of a part A and a part B, when engaged with the machine (asdiscussed in detail hereinafter), the first reactant materials tank cancomprise part A or part B components and vice versa. While in a specificmachine the part A reactant material tank can be configured to engagewith a specific port in the engagement station, as used in thespecification and claims herein, this part A tank can comprise eitherthe first or second (or third or fourth etc.) reactant materials tank.

Each of the part A and part B reactant materials, for example, acatalyst and a polyol, can be incorporated within the respectivereactant materials tank for use with only a small amount of air orsubstantially no air being incorporated therein. In some aspects, afterreactant material is incorporated in each tank, a partial vacuum can beapplied to the tank. It has been found that by ensuring that thereactant materials in each tank remain partially under a vacuum whendelivered from the reactant materials tank, the reactant material willcomprise a lesser propensity to generate bubbles when injected into themold. The substantial absence of gas bubbles in the reactant materialsbefore and after they reach the mold can enhance the finished quality ofthe fabricated part. Yet further, a full vacuum can be applied to thereactant materials tanks so as the reduce the propensity of air bubblesto be generated. For example, a vacuum pressure of about 5 psi belowambient pressure can be established in the filled reactant materialstanks. The tank vacuum (or pressure) can be regulated using a checkvalve in, e.g., the top of the reactant materials tank. As the resinleaves that tank, the check valve can allow a small amount of air intothe reactant materials tank to maintain the desired vacuum (or pressure)in the tank.

As reactant material is removed from each tank when molding operationsare occurring, the amount of internal pressure applied in each tank willaccordingly decrease. Each reactant materials tank can be configured towithstand the maximum pressure reduction to which it is subjected. Thehousing of the reactant materials tank should comprise a material thatcan withstand up to about 29 Hg of internal pressure (or vacuum) when apumping action is applied to an exit port configured to deliver reactantmaterials to fluid communication component for use in the reactioninjection molding process.

The reactant material tanks should also be fabricated from materialsthat are substantially chemically impervious—that is, unreactive andinsoluble—to the reactant materials used in the reaction injectionmolding processes. The housing of the reactant material tanks can befabricated from any material that can suitably store and deliverreactant materials and be able to withstand the pressures to which thetanks are subjected in use. In this regard, the tanks can be made out ofhigh density polyethylene (“HDPE”) generated from injection moldingprocesses, as one example, or stainless steel.

To better enable the reactant materials tank to suitably withstandpressure in use, the interior portion of each reactant materials tankcan comprise one or a plurality of reinforcement structures thatincrease the wall strength of the reactant materials tank in use. In oneaspect, the reactant materials tank reinforcement can comprise aplurality of reinforcing ribs disposed on the interior walls of thereactant materials tank. In another aspect, the reactant materials tankreinforcement structures can comprise at least one or a plurality of“kiss-offs” provided on the interior walls of the reactant materialstank. As would be recognized, a kiss-off comprises the connection of twoclosely spaced parallel walls whereby two relatively weak walls (e.g.,opposing walls in a reactant materials tank formed from HDPE) aremodified into an integral box beam structure that is stronger than theindividual walls. These kiss-offs can be elongated, round or any shapethat provides suitable structural support to the reactant material tanksof the present disclosure.

The strength of each reactant materials tank under pressure can furtherbe enhanced when the reactant materials tank walls are suitably thick.In some aspects, the reactant materials tank walls are at least abouttwo millimeters thick. Yet further, the reactant materials tank wallsare at least about 3 or about 4 or about 5 millimeters thick.

The reaction injection molding machine can be configured with at leastone pump controlled by, for example, a stepper motor, wherein the atleast one pump is in operational engagement with each of the reactantmaterial tanks and the respective fluid communications components so asto generate a first and a second reactant materials fluid stream for thepart A and part B materials in the injection molding process. In someaspects, a single pump is in operational engagement with each reactantmaterials tank. In other aspects, each reactant materials tank is inoperational engagement with at least one pump and a corresponding fluidcommunication component. Suitable pumps for use herein can each,independently, have a total power of about 300 W at 48V, for example.

The reactant material tanks are configurable to generate a signal thatcan notify the user of a fill level to the user via the control orprocessing circuitry. A variety of fill level indicator techniques canbe used. In some aspects, each reactant materials tank can be configuredon the interior thereof with a magnetic float to allow reactant materiallevel to be measured and reported. As would be recognized, magneticfloats can provide information about fill level in a closed system usingthe characteristics of the magnetic field therein. One or more sensors,for example Hall Effect sensors, can read the magnetic fieldcorresponding to a known distance the float is from the sensor(s) togenerate information about the amount of resin left in the tank. In someembodiments, a plurality of Hall Effect sensors can be verticallyaligned along the side of a reactant materials tank to detect theposition of the magnetic float inside the reactant materials tank. Forexample, 16 Hall Effect sensors can be used to detect the currentposition of the magnetic float as it varies with the reactant materiallevel in the tank. In other aspects, the reactant material fill levelcan be obtained for reporting via pressure sensors, weight determinationor the like.

Should the reactant material level in a tank be too low or not enough ina single part of reactant material tanks to allow the user to generatethe desired number of fabricated parts in a run, control or processingcircuitry associated with the reaction injection molding machine can beconfigured to prevent the operation thereof until the user replenishesthe specific tank. Moreover, the reaction injection molding machinecontrol or processing circuitry can be configured to provide a filllevel to the user on demand or continuously during operation. The usercan be notified by an indication or other signal provided on thereaction injection molding machine and/or on a peripheral device, suchas a laptop, tablet, or smartphone. Information about the fill level, aswell as any other relevant operational parameters, can be transmittedfor review to a remote server, or can be stored for later review.

The number of reactant material tanks in the reaction injection moldingmachine engageable with the reaction injection molding machine can vary,while still allowing the machine to comprise the “small footprint”aspect, as discussed previously. In one aspect, about 2 to about 8reactant materials tanks can be engageable with the machine, where eachtank can comprise from about 1 to about 2 gallons of reactant materialin each tank. For operation, the engagement station incorporates atleast two reactant material tanks configured for use with the disclosedmolding technology—that is, part A and part B. These at least tworeactant materials tanks are referred to herein generally as “a firsttank,” and “a second tank,” without reference to whether the first tankor the second tank is the part A or part B, because, for example, theidentity of the materials can be provided by the user and/or confirmedby control or processing circuitry associated with the reactioninjection molding machine.

The reactant material tanks are suitably sized to fit within the machineoverall and the engagement station(s), as well as to facilitate carryingand insertion into the reaction injection molding machine when fullycharged. Multiple tanks of each of the reactant materials can suitablybe incorporated into the reaction injection molding machine to reducethe need to change tanks during a fabrication run. For example, thereaction injection molding machine can be configured with up to about 8gallons of reactant materials (e.g., 4 gallons of part A and 4 gallonsof part B). When more than the at least two reactant material tanks arepresent, the additional tanks can be referred to as the “third reactantmaterials tank,” “fourth reactant materials tank,” “fifth reactantmaterials tank,” “sixth reactant materials tank,” “seventh reactantmaterials tank,” and “eighth reactant materials tank.” Similarly, therespective engagement ports in the reactant materials tank engagementstation can be referred to as the “third reactant materials tankengagement port,” “fourth reactant materials tank engagement port,”“fifth reactant materials tank engagement port,” “sixth reactantmaterials tank engagement port,” “seventh reactant materials tankengagement port,” and “eighth reactant materials tank engagement port.”

While all of part A and part B tanks can be engageable with a singleengagement station, in some configurations, each of the first and secondreactant materials tanks can be configured to engage with separateengagement stations. Irrespective of how many engagement stations areused, each of the engagement stations are operationally configured toprovide fluid communication between the reactant material tanks and theinjection molding mixing nozzle and mold assembly. In this regard, thepart A and part B reactant material tanks can each, independently, beengaged with tank engagement ports that are operationally configuredwith a single engagement station. Yet further, each tank can beconfigured with a single engagement station (and associated tankengagement ports), whereby each of the stations is configured to providefluid communication with the mixing nozzle and the mold assembly.

Yet further, the area proximal to the each of the reactant materialtanks can be configured to provide heat to reduce the propensity of thereactant material to deteriorate upon storage. In this regard, a heatercan be placed proximal to the tanks, where such heater can be augmentedwith a fan. Yet further, the engagement station(s) can be configured toheat the reactant material in conjunction with the generation of a fluidstream of one or both of the reactant materials. The temperatureproximal to the storage tanks can be maintained at from about 15° C.(59° F.) to about 41° C. (105° F.) to ensure consistent reactant qualityin use.

The control or processing circuitry associated with the reactioninjection molding machine can be configured (e.g., via software and/orhardware components) to automatically close the check valve (or otherisolation valve) in an empty (or substantially empty) reactant materialstank, and open the check valve (or other isolation valve) of anothertank that is positioned in the engagement station, where that additionaltank comprises the same reactant material therein. The plurality ofreactant materials tanks can serve as a backup supply of reactantmaterials in the plurality of engagement ports further facilitates theease of operation of the reaction injection molding machine of thepresent disclosure. The control or processing circuitry can also beconfigured to operate the check valves (or other isolation valves) inthe respective engagement ports or stations.

Each of the reactant material tanks can be uniquely tagged or otherwiseidentified. Such tagging or identification can be by RFID, bar codescanning, direct connection circuit (e.g., wires directly connectedbetween the machine and a small chip on the tank), physical marks, andactive systems where communications (e.g., Wifi, Bluetooth, etc.) arenatively embedded on (or in) each of the tanks so that each tankincorporates communications functionality. The reaction injectionmolding machine can incorporate a lock-out mechanism that disables thereaction injection molding machine, for example by disabling the controlor processing circuitry and/or preventing the housing door from beingopened, when an untagged or improperly tagged reactant materials tank isinserted into the reaction injection molding machine by a user.

Moreover, as discussed elsewhere herein, the reaction injection moldingmachine and associated control or processing circuitry allow effectivemonitoring of reactant material usage. Thus, a mismatch between reactantmaterial amounts and monitored reactant material usage can also be usedto generate a lockout or disablement mechanism. Such a lockout ordisablement mechanism can be particularly suitable to ensure thatappropriate reactant material reactant materials are utilized so as toensure that the reaction injection molding machine will remain inoperational condition. The reaction injection molding machine and anyattendant device used to operate the control or processing circuitryassociated therewith can provide the user with a notification of thereason for the lockout or disablement, and further can provide the userwith instructions on how to correct the problem.

In some aspects, the reactant material tanks can be configured forsingle use, and made disposable by a user when the reactant materialstherein when the tank is empty or substantially empty. In other aspects,the tanks can be configured for multiple uses. For multiple uses, thereactant materials tank can be returned to an authorized refillinglocation (e.g., the manufacturer of the reactant materials tank) forrefilling and associated quality control efforts. To ensure that thereaction injection molding machine will operate appropriately, and thatthe resulting pieces or parts are generated to the desired qualitymetrics, the tanks can be configured to allow the reaction injectionmolding machine to detect if a tank has been refilled by a user whensuch improperly refilled tank is inserted into the machine. When a tankhas been refilled in an unauthorized manner, the reaction injectionmolding machine can be configured to lockout or otherwise disable thetank from use. The reaction injection molding machine and any attendantdevice used to operate the control or processing circuitry associatedtherewith can provide the user with a notification of the reason for thelockout or disablement, and further can provide the user withinstructions on how to correct the problem. If the reactant materialstank is refilled by an authorized party, such party can reset thelockout chip that is configured in the reactant materials tank to limitor prevent unauthorized refilling.

As noted, he respective reactant material tanks can be designed forspecific complementary fit in the corresponding engagement port of theengagement station. For example, first reactant material tank can bedesigned to fit only in the reactant materials port associated with thattank, that is, the first reactant materials tank port. As such, secondreactant materials will not fit in that first reactant materials tankport, and the control or processing circuitry associated with thereaction injection molding machine can be configured to notify theoperator of such mismatch. The control or processing circuitryassociated with the reaction injection molding machine can also beconfigured to direct the operator to correct the mismatch. When themismatch is corrected—that is, when the reactant materials port or slotis suitably engaged with first reactant materials tank—the reactioninjection molding machine can again become operational. Yet further, thecontrol or processing circuitry associated with the reaction injectionmolding machine can be configured to confirm that the reactant materialtanks are engaged in the correct port or slot. In this regard, eachreactant materials tank can comprise a unique identifier that isreadable by the reaction injection molding machine and the correctplacement thereof can be confirmed.

Detection that a suitable reactant materials tank is in the appropriateengagement port can be facilitated by mechanical switches, a bar codereader, infrared detectors, RFID or the like. For example, each reactantmaterials tank can include at least one of a RFID tag, opticalrecognition, physical sensing, direct communications from the tank etc.The reaction injection molding machine control or processing circuitrycan report that a reactant materials tank engaged with the port isspent, or that a reactant materials tank was not fabricated by anauthorized source, or refilled in an unauthorized manner, the machine orassociated peripherals in communication with the machine can prompt theuser to insert a new or different reactant materials tank. Moreover, thereaction injection molding machine can include lockouts that prevent thereaction injection molding machine from operating unless the operatorcompletes the directed operations related to the reactant materialstank(s).

The mixing ratios of reactant material parts A and B can be controlledby accurate pumps (e.g., piston pumps driven by stepper motors) that areoperationally engaged the control or processing circuitry (e.g., throughsoftware and/or firmware) of the reaction injection molding machine. Theuse of stepper motors can allow for precise control of the amounts ofreactant material parts A and B used to prepare each fabricated part. Inthis regard, the ratios of the reactant material parts A:B can be in arange from about 1:1 to about 1:1000 (or vice versa). Notably, the closecontrol of reactant material amounts via the stepper motors and the useof components that provide real-time or near real-time information aboutthe amount of reactant material in each tank, the amount of reactantmaterial used can be tracked and monitored.

As would be recognized, the amount of reactant materials used in eachmolding operation is directly related to the volume of the part beingfabricated. In this regard, 8 gallons of reactant material can beexpected to allow fabrication of about 1848 cubic inches (inch³) ofpart(s). This could allow as few as 10 parts to be fabricated from eachgallon of reactant material (for large parts with thick wall sections)to as many as 10,000 parts per gallon for very small parts.

Also, when the user selects a mold for use, the amount of reactantmaterials needed to fill each mold to make a part (that is, to make ashot as well as the total lot of fabricated parts desired in each moldrun) can be generated by the control or processing circuitry associatedwith the reaction injection molding machine. The user can therefore beprovided with detailed information about the number of parts that can befabricated from the reactant materials tanks, cycle times, parts perhour, etc.

In this regard, the present disclosure further provides systems andmethods for managing the operation of an injection molding processcomprising the steps of: selecting a mold for use in the injectionmolding machine of the present disclosure, wherein informationassociated with the fabrication of each part in the mold is provided(i.e., the volume of each resin material receivable into the mold togenerate each part), receiving information about the number of parts tobe fabricated during a molding operation, and providing informationassociated the selection of the resins needed to conduct the moldingoperation. The provided selection information can be in the form ofinstructions to the user to order resins for use. Still further, suchselection can be in the form of automatic ordering instructions to asupplier or the like to provide one or more of resin reactant tanks ormixing nozzles prior to operation of a molding operation associated withthe selected mold. Still further, the systems and methods of the presentdisclosure comprise methods of inventorying, ordering, and using atleast the removably engageable components of the disclosed technologyincluding each of the resin tanks, the molds, and the mixing nozzles.

As discussed elsewhere herein, when installed in the reaction injectionmolding machine, the mold can provide a unique signal that can allow themold identification and design to be discerned and reported. The amountof reactant material used can be further tracked and monitored frominformation about the mold identification and lot size. Detailed reportscan therefore be generated, which can be helpful for quality control,cost evaluation, and regulatory tracking, for example.

In some aspects, the monitoring and tracking of the reactant materialamounts can be used to generate an automatic replenishment of thereactant material tanks via the control or processing circuitryassociated with the reaction injection molding machine. For example, ifthe control or processing circuitry determines that one or more of thereactant material tanks are likely to run out in a period of time, theuser can automatically be provided with additional reactant materialtanks, such as by sending the user an automatic delivery thereof. Thisreplenishment information can be provided by analysis of the usageassociated with a specific reaction injection molding machine, and suchanalysis can be used to generate predictions of when the reactantmaterial tanks will become empty. Alternatively, the user can inputplanned runs with identified molds, and the control or processingcircuitry associated with the machine can generate the amount ofreactant material needed to fabricate those runs and molds can bedetermined. If the determination shows that additional reactant materialwill be needed, the user can be automatically provided with additionalreactant material tanks. Yet further, upon fabrication of a mold for usein the reaction injection molding machine, the user can be provided withthe amount of reactant material suitable along with the mold.

In some aspects, it may be beneficial to stir or otherwise agitate thereactant materials stored in the tanks between uses, especially when thereactant material tanks have been engaged with the engagement station ofthe reaction injection molding machine for use, and have been in usepreviously, but where reactant materials remain the tank and storage isrequired between uses. In this regard, it is possible that users of thereaction injection molding machine may only use the device on a periodicbasis. This is a notable difference between prior art large formatreaction injection molding machine that are typically operatedcontinuously or near continuously in industrial-type settings. Use ofthe reaction injection molding machine periodically could result in thereactant materials becoming altered between periods of use. Agitation ofthe reactant material may be provided by manually shaking the reactantmaterial tank up and down. Kidd-offs of the tank can provide a torturouspath for the resin, helping to mix the resin as it moves around and overthe kiss-offs inside the reactant materials tank.

In certain aspects, the reaction injection molding machine can include arecirculation system that can periodically remove or recirculate rawreactant material from the respective tank to generate agitation so asto reduce the propensity of the specific raw material to become viscousor to solidify. In one example, such a recirculation system candirecting the reactant material from the tank through tubing and/orthrough a solenoid controlled manifold that allows the system toautomatically circulate the reactant material. The recirculation systemcan periodically operate automatically, for example, at least once a dayor once a week or the like. When the reaction injection molding machineis operational for fabricating pieces and parts, the recirculationsystem can be disengaged so as to allow the reactant material reactantmaterials to be circulated to the mixing nozzle as discussed elsewhereherein.

Alternatively, control or processing circuitry associated with thereaction injection molding machine can be configured to alert the userto remove one or more of the reactant material tanks and agitate thetank(s) for a period of time (e.g., about 1 minute) if the control orprocessing circuitry recognizes that the reactant materials tank hasbeen engaged in the machine without being used for a period of time.

Upon activation of a molding operation, part A and part B components areintroduced into a mixing nozzle by way of the respective fluidcommunication components from the reactant material tanks (e.g., viatubing or hoses in communication with the mixing nozzle and therespective reactant material tanks in operational engagement with theengagement station). The fluid streams of reactant materials emanatingfrom each of the first and second reactant material tanks can each,independently, be oriented at an end point become directed into a singlepoint—that is, the mixing nozzle engagement point—defined by a mixingnozzle proximate end, whereby this proximate end is substantially in alocation where the mixing nozzle is engaged with the fluid streams ofthe resin and the catalyst. Each of the fluid flows can terminate in aninjection molding manifold that is engagable with a mixing nozzle.

In use, reactant material parts A and part B are directed into themixing nozzle when a mixing nozzle is securably engaged with the rawmaterials engagement point, such as, via a manifold or comparablecomponent connectable to fluid communication componentry associated withthe raw materials tanks, and mixing is provided by pressure generated byflow of each of the materials into the mixing nozzle. Pressures appliedby the mixed reactants upon entry into the mold can vary depending oneither or both of the reactant materials being used and the particularoperation of the molding process being conducted (e.g., size/shape ofthe mold, part being fabricated etc.). In this regard, pressures can befrom about 1 psi to about 200 psi. Pressures applied to the assembledmold can be from about 1 psi to about 200 psi (pounds per square inch),or about 1, 10, 50, 100, 150 or 200 psi, where any value can form andupper or lower endpoint, as appropriate.

Similarly, rate of flow of the respective reactant materials can bevaried. Such rates of flow can each, independently, be from about 0.01gallon/minute and 1 gallon/minute or from Rate of flow can be from about0.01 gal/minute to about 1 gallon/minute. As would be recognized, therate of flow of each reactant material can be the same or different. Forexample, if the optimum mixing ratio of the catalyst to resin for aparticular molding operation is 1:2 respectively, the rate of flow ofcatalyst to resin can be provided as 1:2. Such flow rates are providedfrom the control or processing circuitry associated with the reactioninjection molding machine and are preset from the mix ratio requirementsof the resin manufacturer.

The mixing nozzles configured to fit the reaction injection moldingmachines of the present disclosure are removably engageable with thereaction injection molding machine at a mixing nozzle engagement pointand with the assembled mold at the mixing nozzle insertion point. Insome aspects, the mixing nozzle used to mix the reactive reactantmaterial components—for example, the catalyst and the resin—areconfigured to allow a user to quickly change out one mixing nozzle foranother. In this regard, once the reactant material reactant materialsare mixed in the nozzle, that nozzle will no longer be suitable for usebecause the mixed materials will quickly cure. Accordingly, the reactioninjection molding machine is configured for single use mixing nozzleswhere such mixing nozzles are removeably engageable with the machine.

The designs/shapes of the mixing nozzles are selected to providerequisite static mixing of the reactant materials. In this regard, themixing nozzles are positioned to force a first reactant material and asecond reactant material to combine as they travel through the length ofthe securably fixed mixing nozzle. The mixing operation can be enhancedthrough inclusion of internal elements in the mixing nozzle (e.g.,baffles, plates etc.) so as to allow the respective fluid streams todivide, recombine, accelerate/decelerate, spread, swirl or form layersas they pass through the mixer. As a result of these alterations in thefluid flow, mixture components are brought into intimate contact.

A user can insert and replace the mixing nozzle from the outside of thereaction injection molding machine. The operator can also open thereaction injection molding machine housing door and engage a mixingnozzle to an empty nozzle engagement point.

In order to allow the mixing nozzle to be removable after fabrication ofa part, the single use mixing nozzle must remain substantially free ofmixed reactant material parts A and B at point where it is mounted. Tothis end, a threaded engagement can be used to engage the mixing nozzleto the fluid exit point. Alternatively, a B-outlet, bayonet, bell, orF-outlet engagement can be used to sealably engage the proximate end ofthe mixing nozzle to the fluid exit point of the reaction injectionmolding machine.

Mixing nozzles suitable for use herein are configured to operationallyengage with the injection molding manifold that is, in turn,operationally engaged with the injection molding machine of the presentdisclosure. Yet further, mixing nozzles suitable for use herein areconfigured to operationally engage with a mold configured for use in theinjection molding machines and methods of the present disclosure.

The disclosed technology further relates to methods of engaging themixing nozzles to the injection molding machine. If necessary, themixing nozzle engagement step is preceded by disengaging the mixingnozzle that was used in a previous molding operation. As described inmore detail hereinafter, the distal end of the mixing nozzle can bedisengaged from the fabricated part via a breaking, twisting, shearingor other type of operation so as to separate a sprue defined by plasticconnecting the distal end of the mixing nozzle with the fabricated part.The mixing nozzle connected at the proximal end to a molded part via thesprue is also considered to be an aspect of the present disclosure. Oncedisengaged from the fabricated part, proximal end of the mixing nozzle,which is still engaged with the mixing nozzle engagement point, can bedisengaged via unthreading or the like.

In some aspects, an automatic mixing nozzle replacement mechanism can beincorporated that can change the mixing nozzle via machine control atthe appropriate time. The mixing nozzles can be configured on a spool orcartridge in such a way that they may be feed through a chamber cyclingfrom one nozzle to the next. The used nozzles can be ejected from themachine with a new nozzle replacing the used nozzle as part of themolding process. This system can be similar to a cartridge loadingsystem commonly seen in air powered nail guns as well as ammunitionfeeds (or clips) in rifles and other auto-loading systems.

When the reaction injection molding machine housing door is open and/orwhen a molding operation is not occurring, the reactant material pumpingoperational components can be locked out or otherwise disengaged so thatreactant materials do not flow through the machine. Again, suchdisengagement or lockout can be effected by the control or processingcircuitry associated with the reaction injection molding machine.

In significant aspects, operation of the reaction injection moldingmachine during a fabrication run should be substantially automatic—or“plug and play”—for the user. To this end, once the user installs themold parts and reactant material tanks, the user should only need toreplace the mixing nozzle in between each fabrication and remove thepart from the machine, along with periodic replacing of the reactantmaterial tanks, if required. In some aspects, the mixing nozzleattachment and disengagement, as well as the mold ejection operation,can be conducted substantially automatically.

In operation, a mold can be provided in two parts that are engageablewithin the mold support framework of reaction injection molding machine,such as by engaging the mold parts with corresponding engagement plates,whereby an assembled mold is provided when the engagement plates holdingthe mold parts are brought together. Upon moldable engagement of the twomold parts, pumping of the reactant materials from the respective tanksthrough the respective fluid communication components into the mixingnozzle can commence. The mixed reactant materials can be introduced intothe assembled mold through a distal end of the mixing nozzle, whereinthe distal end of the mixing nozzle is in fluid communication with atleast a portion of the interior of the assembled mold at the mixingnozzle insertion point. The mixed reactant materials can thereby beintroduced into the assembled mold.

When the total volume of mixed reactant materials needed are introducedinto the mold, the mold will remain closed to allow the material tosuitably cure. As noted, such total volume can be pre-determined andflow rate managed via the control or processing circuitry associatedwith each mold.

As would be recognized, the mixed reactant material parts will commencean exothermic reaction has a time/temp curve that correlates to curepercent of the reactant materials. Typically, this comprises anexponential curve that sets quickly and then starts tapering off. Thepartially cured fabricated part can remain in the mold until it is atleast about 90% or at least about 95% or at least about 98% cured, where“cured” means that there are less than about 10% or 5% or 2% unreactedmaterial remaining. Such a cure time can be about 2 minutes or 5 minutesor 10 minutes or 30 minutes or 90 minutes, depending on the materialsused and the mold/part characteristics, among other things. Accordingly,the number of parts that can be fabricated in the reaction injectionmolding machine can vary. In some aspects, the number of cycles per houris about 2, 5, 10, 20 or 30, where any value can form an upper or lowerendpoint, as appropriate. The number of parts per hour can vary, also.For example, when the fabricated part is small, a multi-cavity tool canbe used, whereby more than 1 part is fabricated in a single moldingoperation. For example, if 50 parts can be fabricated in a singlemulti-cavity mold, 50 parts can be generated in a single molding cycle.If the cycle time for this operation is about 5 minutes, about 250 partscan be fabricated per hour. Family molds can also be used as discussedpreviously.

Parts can be demolded quickly when they are substantially cured, butwhen they are removed from the mold, they could need more time to reach100% cure, and therefore 100% strength, which can occur over hours ordays. Since most parts are not intended for use immediately, this willgenerally not be a problem.

To provide an assembled mold from mold parts that are securably engagedwith respective mold engagement plates, a plurality of stepper motorscan be in operational engagement with a plurality of lead screws. Insome aspects, the number of stepper motors is 4 and the number of leadscrews is 4, however, other arrangements can be used as appropriate forthe design. A plurality of guide rods or guide rails can be associatedwith the mold set up to better ensure that the mold parts are maintainedin place during assembly of the mold and de-molding of the substantiallycured fabricated part. The guide rails can incorporate a plurality ofpins to further secure the mold and associated parts therein.

The stepper motors and associated components can be configured to movethe mold parts together at about 0.1 inch/second to about 10inches/second or at about 1 to about 6 inches/second. Clamping force ofthe mold parts can be up to about 100,000 psi, with a range generally offrom about 1000 to about 15,000 psi. The assembled mold is substantiallyimpermeable to the liquid reactant materials at the seals thereof. Ithas been determined that when such a mold and screw configuration isused, a high amount of clamping force can be generated with minimal useof components. Other ways to bring the mold parts together include theuse of linear actuators or hydraulic/pneumatic cylinders/presses.

In one aspect, the mold plates can be pressed together and the moldassembly—that is, the two mold parts—so as to cause the mold assembly topress against springs at loads of from about 100 to about 1000 pounds.The mold assembly, while pressing against the springs, can cooperatewith the distal end of the mixing nozzle to result in insertion of thatend into a nozzle entry point that forms an opening into the interior ofthe mold assembly. The distal end of the nozzle can extend into theinterior of the mold assembly from about 0.10 inch to about 2.0 inches.Once the distal end of the mixing nozzle is inserted into the manifoldand the mold assembly, the pumps are engaged to cause reactant parts Aand B to be communicated from their respective reactant material tanksto the mixing nozzle, followed by incorporation of the mixed parts A andB into the mold assembly. After a period of time determined by thereaction rate of the mixed resin, which can be automatically provided bythe control or processing circuitry associated with the injectionmolding process, the mold assembly is disengaged from the mixing nozzle.Initiation and completion of such disengagement process can be automatic(e.g., activated by the control or processing circuitry) or manual(e.g., activated by a user) or a combination thereof. With the availablespring force, disengagement of the distal end of the mixing nozzle canbe forced away, thus breaking the plastic sprue that can be present atthe point where the mixing nozzle connects with the fabricated part.This spring action movement therefore breaks the connection between thedistal end of the nozzle and the part allowing the part to be easilyremoved from the mold once the molding cycle is complete.

By way of explanation, once the mixed reactant materials cure in themold, the distal end of the mixing nozzle would normally be “stuck” tothe mold/fabricated part combination since the mixed reactant materialsin the mixing nozzle are all now solid plastic due to curing. With thespring action provide by the disclosed mechanism, after the reactantmaterial parts cure, the plurality of springs push the mold back awayfrom the mixing nozzle and the mold parts open up. The distal end of themixing nozzle, that is, the part of the mixing nozzle that delivers themixed reactant material to the mold through the mixing nozzle insertionpoint, can now be disengaged from the mold and the fabricated part dueto such spring action. In other aspects, the mixing nozzle could beforced away from the fabricated part/mold combination via a solenoid,linear actuator or other suitable system. Yet further, the mixing nozzlecould be manually or mechanically twisted until the fabricated partbreaks away from the mixing nozzle. Still further, a blade or othersharp mechanism could shear off the plastic between the part and mixingnozzle. In yet another example, ejector pins on the sliding mold partwould push the part away from the mixing nozzle. The user can be able toreplace the mixing nozzle by hand, or the nozzle can be automaticallyreplaced as discussed elsewhere herein.

Cycle time, that is the number of cycles that occur in a period of timefrom mold closing to mold opening and is generally different from thecure time, due to the time needed to engage a new mixing nozzle, pumpthe reactant material parts, fabricate the part, remove the part fromthe machine, and remove the used mixing nozzle from the reactioninjection molding machine. To this end, cycle time can vary according tothe size, thickness and complexity of the part being fabricated. In someaspects, the cycle time can be from about 30 seconds to about 60minutes, or about 5 to about 15 minutes. Yet further, cycle time can beabout 1 minute, 5 minutes, 10 minutes, 15 minutes, 20 minutes, 30minutes, 45 minutes or 60 minutes, where any value can form an upper orlower endpoint as appropriate.

In an exemplary process, the mold parts that are attached to the moldassembly plates are brought together at a spring rate of approximately300 pounds. The springs can deflect approximately 1 inch and theassembled mold can engage with the distal end of the mixing nozzle. Themold assembly plates can continue to push together, but can now bepushing against a stop on the reaction injection molding machine,wherein the stop substantially prevents damage to the springs. Aclamping force is applied to seal the mold parts together, where thisforce can be up to about 10,000 psi or greater, in some circumstances.The mixed resin can be injected into the assembled mold via the distalend of the mixing nozzle. The resin can be allowed to set up untilgelling is substantially completed and the part is in a semi-rigidstate, which can be when the resin is about 50% or 60% or 70% of the waythrough the curing process, wherein the clamping pressure can belessened so as to allow the mold assembly to push away from the distalend of the mixing nozzle so as to break the attachment between thenozzle and the partially or fully cured resin in the interior of themold assembly. Once the resin is substantially cured, the mold can beopened and the part can be ejected. The cycle can repeat.

Operation of the reaction injection molding machine can be facilitatedwith indicator lighting on the exterior and/or interior thereof. Forexample, signals can be activated by switches to provide a user withinformation regarding one or more of the following: door close status;injection molding nozzle presence and whether the nozzle is properlyfitted on the reaction injection molding machine; reactant tanks loadand engagement status; power status, etc.

Yet further, operation of the reaction injection molding machine can beenhanced by the addition of lighting on the interior of the housing.Such lighting can also enhance the aesthetics of the machine.Accordingly, the reaction injection molding machine can be configuredwith, for example, LED lighting.

To align with the desktop operation of the disclosed molding technology,the reaction injection molding machine in one aspect can be operated onstandard 120AC, 60 Hz power.

In some aspects, the reaction injection molding machine can incorporatepre-set operations within the firmware associated therewith so as toallow the molds and reactant materials and use thereof to be processedsubstantially without the need for external communications. Suchself-sustained operation can be useful when the reaction injectionmolding machine is operated in a location where Internet access is notavailable. The operations of the reaction injection molding machine whenno Internet is available can be stored within the reaction injectionmolding machine. Moreover, the reaction injection molding machine canalso suitably incorporate communication ports, for example USB ports, orthe like so as to allow the machine to use downloaded operationalinstructions. Such instructions can also be incorporated into thereaction injection molding machine when it is connected to the internetfor use during times when the internet is not available.

In further aspects, the disclosed technology comprises a set of softwareinstructions provided to the control or processing circuitry of thereaction injection molding machine that regulates at least the type andamount of each of the reactant materials including whether either orboth of the reactant materials are in compliance with authorizedreactant material components), the flow rate of each of the reactantmaterials into the mold, the presence or absence of the mold and properconnection thereof with the reaction injection molding machine, theproper closing/seal of the mold parts, the temperature of the mold andreactant materials prior to and during part formation, the time themolds are opened, the pressure at which the molds are opened and closed,the automatic replacement of the mixing nozzle (optional), and theejection of the fabricated part from the mold. Periodic firmware and/orsoftware updates for the control or processing circuitry of the reactioninjection molding machine can also be provided via availablecommunications methodologies.

Information about the conditions of operation of the reaction injectionmolding machine can be provided to the user in real-time orsubstantially in real time. For example, such information can beprovided to the user in “dashboard form” on a mobile device or computer,along with other information such as mold type and identification, runnumber, reactant material details (lot number, type etc), externalconditions (ambient temperature and humidity, etc.) and the like.Process information can also be stored for use at a later date.

Yet further, Bluetooth®, cellular and other types of communications canallow the reaction injection molding machine to communicate directlywith a mobile device or a computer even when internet access is notavailable. In this regard, operations of the reaction injection moldingmachine can be controlled from the mobile device or computer viaapplications (“apps”) or desktop installed software. Informationgenerated by the reaction injection molding machine can further bestored in the mobile device or computer, and such information can laterbe uploaded to the cloud when internet access is again available.

Process information can also be provided to a cloud server in real timeor substantially real time to allow a third party to observe and managethe operation of the reaction injection molding machine from a remotelocation.

In some aspects, the reaction injection molding machine can beconfigured to allow replacement of operational componentry (e.g.,components, circuitry or other parts) while the reaction injectionmolding machine is deployed by the user. During extended use, it ispossible that the tank engagement, pumping, molding componentry or otherparts of the reaction injection molding machine will fully or partiallyfail. To facilitate repair of the reaction injection molding machine bya user, one or more aspects of the reaction injection molding machinecomponentry can be configured to be individually removable. In otherwords, one or more of the reactant materials tank engagement, pumpingsystem (tubing, pumps and/or step motors), and mold supports and relatedcomponentry can be engageably removable from the reaction injectionmolding machine. Such modular configuration allows the user to be sent akit associated with the part(s) of the reaction injection moldingmachine that are not operational whereby the user can disengage thecomponent to be replaced from the reaction injection molding machine andto replace that failed component with a functional component so that thereaction injection molding machine can again be utilized. Uponreplacement of the component, the control or processing circuitryassociated with the reaction injection molding machine can be configuredto conduct a validation procedure to ensure that the component isreplaced correctly. The component that is replaced can incorporateidentification to allow the component to be tracked. In relation to thisaspect, the disclosed technology further provides a method for repairinga reaction injection molding machine of the present disclosure.

The articles or parts fabricated herein are suitable for use in any usein which thermosetting polymeric parts made in traditional processes canbe used. Accordingly, resin selection will generally define acceptableuse cases for the resulting parts. When the resulting articles or partsare biocompatible or otherwise non-reactive or non-allergenic to humansor animals, medical devices can be generated, including implantablemedical components. When food grade plastics are generated from thethermoplastic resins, the articles or can be used for food preparation,shipping or storage.

The format and operation of the reaction injection molding machines andmethods of the present disclosure are particularly suitable for rapidprototyping. As would be recognized, “rapid prototyping” is used tocreate a three-dimensional model of a part or product. In addition toproviding 3D visualization for digitally rendered items, rapidprototyping can be used to test the efficiency of a part or productdesign before it is manufactured in larger quantities. Such testing canbe useful when evaluating the shape or design of an article or part orcollection of article or parts assembled into a product.

Yet further, the reaction injection molding machines and methods hereincan beneficially be used to generate parts or articles on an “on demand”basis, such as in substantially real time. Moreover, when used inconjunction with the 3D printed molds as discussed herein, customizedarticles and parts can generated exceedingly quickly vs. prior artmethods.

While such customization can be useful in a variety of settings, suchsubstantially real time article or part generation can be used togenerate medical equipment intended for use by a patient in accordanceto specifications associated with the patient's medical condition. Such“patient-matched” devices can include instrumentation (e.g., guides toassist with proper surgical placement of a device), implants (e.g.,joints, stents, scaffoldings), and external devices (e.g., prosthesis,supports/braces/casts). Patient-matched (or patient-specific) devicesare created specifically for the patient based on individual features,such as anatomy. They can be based on a template model that is matchedto a patient using medical imaging. Patient-matching can be accomplishedby techniques such as scaling of the device using one or more anatomicfeatures from patient data.

Such medical devices can also be generated in small runs, thus allowingdevices to be generated for a patient population of a relatively smallsize. For example, runs of less than about 5000 or less than about 1000or less than about 500 or less than about 100 devices can be made costeffectively using the reaction injection molding machines and methodsherein. As a result, it is expected that medical costs can be reducedwhen hospitals or other medical facilities, etc. adopt the disclosedmachines and methods.

Referring to FIG. 1, presented is a front view of a reaction injectionmolding machine 100 of the present disclosure that comprises a housing105 that includes a door 110 for access into the interior of machine100. As shown, the door 110 can have a front door aspect 110 a and topdoor aspect 110 b, to facilitate frontal access into machine 100 or fullaccess into the interior therein. The door 110 can also include a latch110 c to facilitate opening and closing of door 110. A door sensor suchas, e.g., a switch or proximity sensor can be included to detect doorclosure. Left hinges 115 a, 115 b and right hinges 120 a and 120 b areshown in FIG. 1. The hinges 115 and 120 connect the door panels togetherand allow for jointed motion of the front and top door aspects 110 a and110 b. The door 110 can be openably attached to housing 105 by hinges asillustrated in FIG. 2, but as would be appreciated other forms ofhinging can be used to allow access into machine 100.

Further in FIG. 1, reactant materials tanks 125, 130, 135 and 140 areshown that, in the configuration shown, can comprise two reactantmaterials tanks of part A (e.g., tanks 125 and 130), and two reactantmaterials tanks of part B (e.g., tanks 135 and 140). Other tankpositions and/or combinations are contemplated. Insertion and removal ofthe respective reactant materials tanks 125-140 can be facilitated bylatching mechanisms 145, 150, 155 and 160, respectively. Each reactantmaterials tank can, independently, be released from engagement with arespective reactant material tank engagement port (not shown) bydepressing or pulling the mechanisms 145, 150, 155 and 160. A fan 165can be incorporated into housing 105, with an exemplary placement shown,although other placements of fan 165 are contemplated. Edges of thehousing 105 can be chamfered, as shown, for example, by corner 170, andtransport of machine 100 can be facilitated by indentations in thehousing 105 as shown by, for example, 175 a, 175 b and 175 c (see FIG.3), and 175 d (see FIG. 2).

FIG. 2 shows a rear view of the reaction injection molding machine 100of the present disclosure. Top door aspect 110 b of door 110 is shownattached to housing 105 by left hinges 205 a, 205 b and right hinges 210a and 210 b. Again, other door attachment methods are contemplated.

FIG. 3 illustrates another view of the reaction injection moldingmachine 100 of the present disclosure wherein front door aspect 110 a isopen to allow access into the interior of the housing 105 via door latch110 c. First mold guide pair 305 a and 305 b are mounted on a rail 310that is securely attachable with or to a first side of first moldengagement plate 315. Not shown in FIG. 3 is a second mold guide pair320 a and 320 b and second rail 325 (see FIG. 7) that are securelyattachable with an interior side of a second mold engagement plate 330.A plurality of lead screws 335, 340, 345 and 350 (see FIG. 4) areoperably engageable with the molding engagement componentry (e.g., 305a, 305 b, 310, 315, 320 a, 320 b, 325 and 330), as well as a pluralityof stepper motors 435, 440, 445 and 450 (see FIG. 4).

Turning now to FIG. 4, an example of a mold support framework 400 of thereaction injection molding machine 100 of the present disclosure isshown (note that the perspective is flipped from that of FIG. 3). Inthis regard, FIG. 4 shows mold guides 305 a and 305 b engaged with rail310, wherein rail 310 is connectably engaged with guide rails 405 and410. While a configuration with only two guide rails 405 and 410 isshown, other guide rail configurations are contemplated. The guide rails405 and 410 can include coatings and/or lubrication to facilitate smoothmovement of the first mold engagement plate 315 along the guide rails.

FIG. 4 further illustrates complementary first and second mold supportplates 415 and 420 at opposite ends of the mold support framework 400,wherein securing rail 425 is shown to allow mold support framework 400to be removably attachable to the housing 105 via at least one screwhole 430, although other attachment arrangements are contemplated. Forexample, securing rail 425 can extend along the bottom of the moldsupport framework 400 between the first and second mold support plates415 and 420 and can include holes or other openings at its corners forattachment to the housing 105.

FIG. 4 further illustrates an exemplary arrangement for movement of moldengagement plate 315 toward mold engagement plate 330 during a moldingoperation. In this regard, the plurality of stepper motors 435, 440,445, and 450 are removably attached to an outer side of second moldsupport plate 420. The plurality of stepper motors 435, 440, 445, and450 are operationally engaged with respective lead screws 335, 340, 345,and 350. In the example of FIG. 4, the stepper motors 435, 440, 445, and450 are engaged with the lead screws 335, 340, 345, and 350 throughbelts and pulleys. By using a larger pulley on the lead screws, a finerstep resolution can be achieved. Pulley teeth and belt notches can beused to ensure synchronization of the motors 435, 440, 445, and 450 andlead screws 335, 340, 345, and 350. Belt tension can be adjusted throughpivot plates supporting the stepper motors 435, 440, 445, and 450. Thepivot plates can be secured in position against the second mold supportplate 420 using mounting screws or bolts. Other configurations such asgears can also be used. In use, operation of the stepper motors 435,440, 445, and 450 will cause the first and second mold engagement plates315 and 330 to be brought together, thereby bringing the respective moldparts (see FIGS. 8A-8C) together so as to generate an assembled mold.

FIG. 4 also illustrates a plurality of mold support engagements 460,here denoted 460 a, 460 b, 460 c, 460 d, 460 e, 460 f, 460 g, 460 h, and460 i, where fewer or more of such support engagements can beincorporated in each of the first and second mold engagement plates 315and 330. Such mold support engagements 460 can be sized to fit oncorresponding fasteners, for example bolts, screws, pins, etc., that canbe fixed to first and second mold engagement plates 315 and 330. Themold support engagements 460 and any associated bolts or otherappropriate fasteners can be used to assist in attaching the mold parts(not shown) to the first and second mold engagement plates 315 and 330.Different numbers and arrangements of mold support engagements 460 andassociated fasteners can be used for different mold configurations.Thus, an assortment of mold engagement supports 460 can be incorporatedin the first and second mold engagement plates 315 and 330. Moldsfabricated for use in the present disclosure can be configured toincorporate appropriate configurations of complementary fasteners toallow mating with one or a plurality of mold support engagements 460located on first and second mold engagement plates 315 and 330, asappropriate.

FIG. 4 also illustrates injection molding manifold 465 having injectionmolding manifold fluid communication ports 470 and 475, as will bediscussed later in relation to FIG. 7.

Referring next to FIG. 5, a callout 500 of an arrangement of theplurality of reactant materials tanks 125, 130, 135, and 140 isillustrated, whereby certain features thereof have been illustrated inexemplary fashion. The reactant materials tanks 125, 130, 135, and 140can incorporate a number of features to facilitate their use. Forexample, as shown with respect to reactant materials tank 140, a carryhandle 505 can be integrated into the container. A second handle can beincluded as shown to aid in installation of the reactant materials tank.Yet further, a hole 510 can be incorporated so as to allow the reactantmaterial tank to be hung on a peg or the like (not shown) when notinstalled in the reaction injection molding machine 100.

As discussed in detail elsewhere herein, each reactant material tank canincorporate one or a plurality of kiss-offs 515 to enhance the overallstrength of the reactant materials tanks 125, 130, 135, and 140 whenreactant material is being removed therefrom. FIG. 5 illustrates twelvekiss offs extending through reactant material tank 140, however, more orfewer, or larger or smaller, kiss-off configurations can be used. Aspreviously discussed, the kiss-offs 515 can provide a tortuous path forthe resin to remain mixed. For example, the resin can be manually mixedby shaking the reactant materials tank. The illustrated reactantmaterial tanks 125, 130, 135, and 140 can be sized to incorporate abouttwo gallons of reactant material in each tank, however, larger orsmaller capacity tanks can be used, as long as the small footprintaspects of the reaction injection molding machine of the presentdisclosure is appropriately enabled.

Still with respect to FIG. 5, key-way 520 (shown as ½ of the component520 a) is incorporated on engagement station 525 so as to ensure thatthe right tanks are properly engaged. In this regard, to ensure thatpart A is not inserted into the part B engagement ports (and vice versa)key-way 520 is configurable to lock-out (or prevent insertion of) thewrong raw materials tanks, so as to prevent the reaction injectionmolding machine 100 from being disabled as a result of incorrectplacement of raw materials into the respective engagement ports. Forexample, the key-way 520 can comprise one or more open or covered slots(or grooves) located on one or both sides that allow the one or morekeys (e.g., tabs or protrusions) on one or more sides of the reactantmaterials tanks to slide into during installation of the correspondingreactant materials tank. By utilizing different slot and keyconfigurations, wrong reactant materials tank can be prevented frombeing installed. For instance, type A reactant materials tanks caninclude a single key that aligns with a single slot in the type Akey-ways and type B reactant materials tanks can include two keys thatalign with two offset slots in the type B key-ways. By providingdifferent number and alignments of the keys and slots, lockouts can beprovided to avoid installation of the wrong reactant materials tank inthe wrong engagement port.

The mouths (not shown) of reactant materials tanks 135 and 140 can each,independently, be engaged with a reactant material tank engagementstation 525 by way of respective engagement ports 530 and 535 (see FIG.6A). Reactant materials tanks 125 and 130 can similarly engage withengagement station 540. Generally, sealed engagement of the reactantmaterials tanks 125-140 with the engagements ports can by way of a checkvalve, as discussed elsewhere herein. Insertion and removal of therespective reactant materials tanks 125, 130, 135 and 140 can befacilitated by mechanical linkages of latching mechanisms 145, 150, 155and 160, respectively. Each reactant materials tank can, independently,be released from engagement with a respective reactant material tankengagement port 530 or 535 by depressing or pulling the latchingmechanisms 145, 150, 155 and 160. The linear movement of depressing abutton or pulling a handle of the latching mechanisms can be translatedinto rotational movement of a locking mechanism by the mechanicallinkages to allow removal of the installed reactant materials tank, toallowing insertion of a reactant materials tank. Release of the latchingmechanism after insertion can allow spring action to return the lockingmechanism to a locked position and secure the mouth of the reactantmaterials tank in the engagement port.

When appropriately engaged in the respective engagement ports 530 and535 (see FIG. 6A), the reactive materials in tanks 135 and/or 140 can beintroduced into a first reactive material fluid stream by way of one ora plurality of pumps. Similarly, the reactive materials in tanks 125 and130 can be introduced into a second reactive material fluid stream usingone or a plurality of pumps. An exemplary pump arrangement isillustrated in FIG. 5 as two pumps 545 and 550 that are enclosed withinthe pumping station 555. Piston style pumps can be used. Varying thespeed can adjust volume of reactant supplied by the pump and/ordischarge pressure. When two pumps are used, as here, the first andsecond reactant material fluid streams can be simultaneously pumped atdifferent rates in accordance with the parameters of the associatedmolding operation. In some aspects, only one of the reactive materialtanks of parts A and B will be used at a time. This can be accomplishedthrough control of the check valves, or through other isolation valves,associated with the engagement stations 525 and 540. When a reactantmaterials tank 125-140 is empty (as indicated by sensors as discussedhereinafter), that reactant materials tank can be isolated from thecorresponding reactive material fluid stream and the second tank canbecome operable.

Further by way of illustration, pumping station 555 incorporates fluidcommunication ports 560 a and 560 b and 565 a and 565 b through whichreactant material can flow from the respective tanks 135 and 140, whenpumping station 555 is engaged with the reactant material engagementstation 525. A secure fit between pumping station 555 and reactantmaterial engagement station 525 can be facilitated by a friction fitprovided by indentations in one or more of 525 and 555, such as shown by570. Other forms of secure fit are contemplated. Reactive materialengagement station 540 can similarly be securely engaged with pumpingstation 555.

FIG. 6A shows details of an exemplary cross-sectional view 600 of aconfiguration of two reactant material tanks, for example, 135 and 140,when loaded into reactant material engagement station 525. Threadedmouths 605 and 610 are shown on tanks 135 and 140, respectively. Priorto use, or for storage, reactant materials tanks 135 and 140 can besealed via a threaded cap (not shown) or the like. Other forms ofclosures are contemplated.

As shown in FIG. 6A, each of raw materials tanks 135 and 140 incorporatecheck valves in the mouths thereof, as shown by 615 and 620,respectively. Each of engagement ports 530 and 535 incorporate checkvalves 625 and 630 therein. By way of example, when reactant materialstank 140 is engaged with engagement port 535, such engagement will causecheck valves 620 and 630 to open by way of spring action to allowreactant material to flow from tank 140 into fluid flow chamber 635 inengagement station 525. The check valves 620 and 630 can act againsteach other to facilitate reactant flow into the reactant material fluidstream. The latching mechanism 160 (FIG. 5) can lock the threaded mouth610 of the reactant materials tank 140 in position in the engagementport 535. When the reactant materials tank 140 is removed from theengagement port 535, both check valves 620 and 630 automatically closepreventing any loss or leakage from the reactant materials tank 140during removal and sealing the system when the tank is not present.

Key-way 520 and 640 are shown in cross-section as components 520 a, 640a, 520 b and 640 b in FIG. 6A. Referring to FIG. 6B, the example ofkey-way 520 will be described. In this regard, key-way 520 is shown as atop-cross section that secures a bottom-portion of tank 140. An interiorportion of key-way 520 can incorporate a detent 645 (e.g., slot orgroove) that is configured to mate with a complementary protrusion 650(e.g., key or tab). Only tanks specifically configured with detentsconfigured to mate with complementary protrusions will be engageable soas to ensure that part A tanks are not placed into part B engagementports, and vice versa. In one implementation, among others, part Areactant materials tanks can include one key centered on the mouth areaof the reactant materials tank and part B reactant materials tanks caninclude two parallel keys with the space between the keys centered onthe mouth area of the reactant materials tank. FIG. 6C is a perspectiveview of reactant materials tank 140 inserted in key-way 520 including asingle detent (or covered groove) 645.

Turning back to FIG. 6A, tanks 135 and 140 are shown partially filledwith raw material 655 and 660, respectively. Floats 665 and 670 areshown proximal to an upper surface of the raw material 655 and 660,respectively. Floats 665 and 670 are configurable with sensors (e.g., aplurality of Hall Effect sensors), here magnets 675 and 680, moveablyconfigured on support columns 685 and 690, where the sensors areoperably engaged with a complementary sensor signal receiver (not shown)that provides information about the fill level of each of the tanks inuse. One or more sensors, for example Hall Effect sensors, can read themagnetic field corresponding to a known distance the float is from thesensor(s) to generate information about the amount of resin left in thetank. A plurality of Hall Effect sensors can be vertically aligned alongthe side of a reactant materials tank to detect the position of themagnetic float inside the reactant materials tank. In someimplementations, a combination of the highest magnetic readings can beused to determine the reactant level in the tank. For instance, thethree highest readings taken from a stack of Hall Effect sensorsadjacent to the reactant materials tank can be used to determine theamount (or percent) resin remaining in the tank.

Now with respect to FIG. 7, is a view of the molding assembly 700 of thereaction injection molding machine 100 with the housing 105 removed. Afirst fluid connection port 705 is sealably engagable with a firstreactant materials fluid stream via a first hose 710. A second fluidconnection port 715 is sealably engageable with a second reactantmaterials fluid stream via a second hose 720. Hoses 710 and 720 aresealingly engageable with connector port 770 which is operationallyengaged via an injection molding manifold 765 with the proximal end 780(see FIG. 8A) of injection molding nozzle 775 (see FIG. 8A). Theinjection molding nozzle 775 extends through mold support plate 420 withthe distal end 785 in the space defined by the distance between plates420 and 330, and aligned with a chamber opening 790 through mold support330.

FIGS. 8A-8D illustrate an exemplary operation of the reaction injectionmolding machine 100 of the present disclosure. FIG. 8A shows aconfiguration where a first mold part 805 and second mold part 810 areremovably mounted on mold engagement plates 315 and 330, respectively.On an interior side of the mold engagement plate 330 (that is, the sideproximal to mold support plate 420), springs 815 a and 815 b areoperationally engaged with mold engagement plate 330 and mold supportplate 420. Second mold part 810 includes an opening (not shown) inoperational engagement with chamber opening 790 disposed through moldsupport plate 330. The springs 815 can comprise two or more springs 815.For example, two, four or other combination of springs 815 can bedistributed about the chamber opening 790 to provide even separationpressure to disengage the injection molding nozzle 775 from the secondmold part 810 and mold engagement plate 330.

FIG. 8A also illustrates a configuration for engagement of mixing nozzle775. Mixing nozzle 775 is connectably engaged with connector port 770 bysecuring of a proximal end 780 of the mixing nozzle 775 using, e.g., abayonet-type attachment. Once securely attached to connector port 770,the distal end 785 of the mixing nozzle 775 is ready for placement intomixing manifold 465 by engagement of connector port 770 in manifold port480. With the mixing nozzle attached to the connector port 770, therewill be fluid engagement with the part A and part B reactant materialtanks via hoses 710 and 720 and pumps 545 and 550 (see FIG. 7). Wheninstalled in the injection molding manifold 465, the injection moldingnozzle 775 extends through mold support plate 420 with the distal end785 in the space defined by the distance between plates 420 and 330, andaligned with the chamber opening 790 through mold support 330 as shownin FIG. 8B.

Referring to FIG. 8B, movement between mold engagement plates 315 and330 is shown, where advancement is by way of the lead screws 335, 340,345, and 350 and stepper motors 435, 440, 445, and 450 (see FIG. 4).Control of the stepper motors 435-450 advances the mold engagement plate315 and the first mold part 805 along the guide rails 405 and 410 asindicated by the arrow. Encoders on each of the lead screws or steppermotors can be used to provide feedback that allows for precisedetermination of the location of the corners of the mold engagementplate 315, and thus the relationship between the mating faces of thefirst and second mold part 805 and 810. As the mold engagement plates315 and 330 move closer together, the mating faces of the mold parts 805and 810 contact to form the assembled mold. After initial contactbetween the mold parts, the lead screws continue to move the moldengagement plate 315 in the indicated direction, thereby movingengagement plate 330 along the guide rails 405 and 410, and compressingthe springs 815 between the mold engagement plate 330 and mold supportplate 420. As the springs 815 are compressed, the distal end 785 of themixing nozzle 775 moves through the chamber opening 790 and into acorresponding opening in the second mold part 810 as shown in FIG. 8C.

Referring to FIG. 8C, the first mold part 805 and second mold part 810are brought together to sealingly engage to form an assembled mold 820suitable for injection molding. The path defined by the chamber opening790 through mold support 330 and up to second mold part 810 isconfigured to allow at least a portion of mixing nozzle distal end 785to penetrate the outer surface of the second mold part 810 so as toallow introduction of injection molding raw materials (e.g., reactantmaterials or resins) after being mixed in mixing nozzle 775 by way ofdistal end 785. The pumps 545 and 550 (see FIG. 7) can control theinjection volume and pressure of the reactant materials supplied to theassembled mold 820. After injection of the reactant materials, the moldparts 805 and 810 are maintained in position to allow for curing beforedisassembly and extraction of the molded part.

FIG. 8D shows a configuration after the raw materials have beenintroduced into mold 820, and at least some curing has taken place. Thestepper motors 435, 440, 445, and 450 can reverse the rotationaldirection of the lead screws 335, 340, 345, and 350 to pull the moldengagement plate 315 and first mold part 805 away from the second moldpart 810. As the mold engagement plate 315 is moved back, the springs815 force the other mold engagement plate 330 to move in the samedirection. The spring force can separate the distal end 785 of themixing nozzle 775 to separate from the molded part in the assembledmold. As the mold engagement plate 330 moves, the springs 815 begin todecompress and apply less pressure until a stopping point is reached. Atthat point, the lead screws 335-350 continue to move the first mold part805 away from the second mold part 810. One or more mechanical stops canbe provided to prevent further movement of the mold engagement plate 330and the second mold part 810. For example, pins can be mounted to extendthrough openings in the mold engagement plate 315 and contact the othermold engagement plate 330 to prevent movement beyond that point. Thepartially cured or fully cured part 825 (shown in partial) will bedisengageable from second mold part 810 after breaking the sprue 830 bythe force applied by springs 815 a and 815 b, or the sprue 830 can becut to allow the partially or fully cured molded part 825 to beremoveable from the first mold part 810.

Referring next to FIG. 9, shown is an example of the control orprocessing circuitry 900 of a reaction injection molding machine 100.The control or processing circuitry 900 can include at least oneprocessor circuit, for example, having a processor 903 and a memory 906,both of which are coupled to a local interface 909. The local interface909 can comprise, for example, a data bus with an accompanyingaddress/control bus or other bus structure as can be appreciated. Aninput/output (I/O) interface 912 allows for user input and/ornotification. For example, the I/O interface 912 can provide for manualmold movement, manual purge, provisioning of resin, start and/or stop.The control or processing circuitry 900 can also include one or morecommunication interface(s) 915 that can facilitate communications with auser device 918 and/or one or more remotely located server(s) 921. Thecommunication interface(s) 915 can be configured to support, e.g., WiFi,Bluetooth®, Cellular, or other wired and/or wireless communicationsbetween devices, either directly or through a network 918 (e.g., theInternet, WAN, LAN, or cellular network). To this end, the user device921 may comprise, for example, a portable device such as laptop, tablet,smart phone, personal digital assistant, or other computing device. Theserver(s) 924 can comprise computing devices and data storage.

Executed within the user device 921 are various applications including amolding interface application 927. Execution of the molding interfaceapplication 927 allows for communication between the user device 921 andthe reaction injection molding machine 100. Status information of thereaction injection molding machine 100 can be provided to a user througha display device 930. The user may also be able to provide commands andother instructions that can be implemented by the reaction injectionmolding machine 100. The remotely located server(s) 924 can includemolding data and/or programs that can be accessed by the reactioninjection molding machine 100. In this way, information regarding moldsand/or reactant materials can be accessed and/or updated through acentralized data base. The server(s) 924 may also automatically updateapplications (or application modules) installed in the reactantmaterials molding machine 100.

The control or processing circuitry 900 can communicate with varioussensors 936 distributed about the reaction injection molding machine 100to obtain information about the operational status of the process. Tothis end, sensor interfaces can be included in the control or processingcircuitry 900 to allow for communication with the sensors 936. Sensors936 can include, but are not limited to, inlet sensors such as opticaldetectors and/or physical switches for detecting when mixing nozzle isinstalled and locked in position. Pressure and/or temperature sensorscan also be included for each mold engagement station. Encoders or otherposition sensors can be used to detect position of the mold parts 805and 810 during the molding process. Current sensors can also bedistributed about the control or processing circuitry 900 to sense andvalidate clamp and/or pump motor operation, or to validate fanoperation. Switches can be provided to sense when the access doors 110are closed. Reactant material tank sensors can include proximity sensorsto detect the presence of installed tanks and level sensors as have beendiscussed. The control or processing circuitry 900 can also comprise acomponent identification (ID) interface 939 that facilitates theacquisition of ID information for installed mold parts 805 and 810and/or reactant materials tanks 125, 130, 135 and 140. For example, thecomponent ID interface 927 can be a radio frequency ID (RFID) interfacethat can communicate with RFIDs embedded in or affixed to the mold partsand/or reactant materials tanks.

Stored in the memory 906 are both data and several software componentsthat are executable by the processor(s) 903. In particular, stored inthe memory 906 and executable by the processor(s) 903 can be variousmolding applications and/or modules 942 such as, e.g., a molding processapplication, a mold identification module, a reactant materialsidentification module, and/or other applications and/or modules. Alsostored in the memory 906 may be a data store 945 and other data (e.g.,mold and/or resin information). In addition, an operating system 948 maybe stored in the memory 906 and executable by the processor(s) 903.

It is understood that there may be other applications that are stored inthe memory 906 and are executable by the processor(s) 903 as can beappreciated. Where any component discussed herein is implemented in theform of software, any one of a number of programming languages may beemployed such as, for example, C, C++, C#, Objective C, Java®,JavaScript®, Perl, PHP, Visual Basic®, Python®, Ruby, Delphi®, Flash®,or other programming languages.

A number of software components are stored in the memory 906 and areexecutable by the processor(s) 903. In this respect, the term“executable” means a program file that is in a form that can ultimatelybe run by the processor(s) 903. Examples of executable programs may be,for example, a compiled program that can be translated into machine codein a format that can be loaded into a random access portion of thememory 906 and run by the processor 903, source code that may beexpressed in proper format such as object code that is capable of beingloaded into a random access portion of the memory 906 and executed bythe processor 903, or source code that may be interpreted by anotherexecutable program to generate instructions in a random access portionof the memory 906 to be executed by the processor 903, etc. Anexecutable program may be stored in any portion or component of thememory 906 including, for example, random access memory (RAM), read-onlymemory (ROM), hard drive, solid-state drive, USB flash drive, memorycard, optical disc such as compact disc (CD) or digital versatile disc(DVD), or other memory components.

The memory 906 is defined herein as including both volatile andnonvolatile memory and data storage components. Volatile components arethose that do not retain data values upon loss of power. Nonvolatilecomponents are those that retain data upon a loss of power. Thus, thememory 906 may comprise, for example, random access memory (RAM),read-only memory (ROM), hard disk drives, solid-state drives, USB flashdrives, memory cards accessed via a memory card reader, floppy disksaccessed via an associated floppy disk drive, optical discs accessed viaan optical disc drive, magnetic tapes accessed via an appropriate tapedrive, and/or other memory components, or a combination of any two ormore of these memory components. In addition, the RAM may comprise, forexample, static random access memory (SRAM), dynamic random accessmemory (DRAM), or magnetic random access memory (MRAM) and other suchdevices. The ROM may comprise, for example, a programmable read-onlymemory (PROM), an erasable programmable read-only memory (EPROM), anelectrically erasable programmable read-only memory (EEPROM), or otherlike memory device.

Also, the processor 903 may represent multiple processors 903 and thememory 906 may represent multiple memories 906 that operate in parallelprocessing circuits, respectively. In such a case, the local interface909 may be an appropriate network that facilitates communication betweenany two of the multiple processors 903, between any processor 903 andany of the memories 906, or between any two of the memories 906, etc.The local interface 909 may comprise additional systems designed tocoordinate this communication, including, for example, performing loadbalancing. The processor 903 may be of electrical or of some otheravailable construction.

Although the molding application(s) and/or module(s) 942, and othervarious systems described herein may be embodied in software or codeexecuted by general purpose hardware as discussed above, as analternative the same may also be embodied in dedicated hardware or acombination of software/general purpose hardware and dedicated hardware.If embodied in dedicated hardware, each can be implemented as a circuitor state machine that employs any one of or a combination of a number oftechnologies. These technologies may include, but are not limited to,discrete logic circuits having logic gates for implementing variouslogic functions upon an application of one or more data signals,application specific integrated circuits having appropriate logic gates,or other components, etc. Such technologies are generally well known bythose skilled in the art and, consequently, are not described in detailherein.

Also, any logic or application described herein, including the moldingapplication(s) and/o module(s) 429, and/or other application(s), thatcomprise software or code can be embodied in any non-transitorycomputer-readable medium for use by or in connection with an instructionexecution system such as, for example, a processor 903 in a computersystem or other system. In this sense, the logic may comprise, forexample, statements including instructions and declarations that can befetched from the computer-readable medium and executed by theinstruction execution system. In the context of the present disclosure,a “computer-readable medium” can be any medium that can contain, store,or maintain the logic or application described herein for use by or inconnection with the instruction execution system. The computer-readablemedium can comprise any one of many physical media such as, for example,magnetic, optical, or semiconductor media. More specific examples of asuitable computer-readable medium would include, but are not limited to,magnetic tapes, magnetic floppy diskettes, magnetic hard drives, memorycards, solid-state drives, USB flash drives, or optical discs. Also, thecomputer-readable medium may be a random access memory (RAM) including,for example, static random access memory (SRAM) and dynamic randomaccess memory (DRAM), or magnetic random access memory (MRAM). Inaddition, the computer-readable medium may be a read-only memory (ROM),a programmable read-only memory (PROM), an erasable programmableread-only memory (EPROM), an electrically erasable programmableread-only memory (EEPROM), or other type of memory device.

Referring now to FIG. 10, shown in a flow diagram illustrating anexample of the operation of the reaction injection molding machine 100.Operation of the reaction injection molding machine 100 can start by,e.g., pressing a start “button” on the I/O interface 912 (see FIG. 9).This can initiate execution of one or more molding applications and/ormodules 492 that can cause the control or processing circuitry to begina molding process. At 1003, the control or processing circuitry 900 caninitially check the components and operating status of the reactioninjection molding machine 100. For example, the presence of reactantmaterials tanks 125, 130, 135 and/or 140 (see FIG. 5) can be check usingoptical or other proximity sensors. The resins present in the reactantmaterials tanks can be determined using the component ID interface 939(see FIG. 9) to obtain the identification information for each installedtank. The mold parts 805 and 810 installed in the reaction injectionmolding machine 100 can also be determined using the component IDinterface 939 to read their RFIDs. Temperature of the first and secondreactant materials fluid streams can also be checked using, e.g.,resistance temperature detectors (RTDs) in the engagement stations 525and 540.

Based on the obtained information, the current installation can bedetermined and the mold parameters loaded at 1006. Parameter informationfor previously used mold (or known) parts 805 and 810 can be obtainedfrom the data store 945 (see FIG. 9) or parameter information for newmold (or unknown) parts 850 and 810 can be obtained from remotelylocated server(s) 924 through the communication interface 915 (see FIG.9). The parameters can be validated at 1009 to ensure that the moldparts 805 and 810 match and the resin in the installed reactantmaterials tanks 125-140 is compatible with the mold parts. Ifcompatibility is confirmed, the doors 110 (see FIG. 1) are confirmedclosed through proximity sensors and locked at 1012 to prevent accessduring the molding cycle.

With the doors 110 secured, the mold parts 805 and 810 can be runtogether or closed at 1015 as described with respect to FIGS. 8A-8C. Thecontrol or processing circuitry can control the stepper motors 435, 440,445, and 450 (see FIG. 4) to ensure that corners of the mold engagementplate 315 are driven to align the mold parts appropriately. The speedcontrol can ensure fast operation and a high clamping force for theassembled mold 820 (see FIG. 8C). With the mold parts 805 and 810clamped together, and the injection molding nozzle 775 inserted throughmold engagement plate 330 into the assembled mold 820 (see FIG. 8C),resin can be pumped (or injected) into the mold cavity at 1018 based onthe mold parameters. The pressure and volume of each reactant materialcan be monitored and controlled by the control or processing circuitry.After the injection is completed, the assembled mold 802 remains clampedtogether for resin curing at 1021. The time period for curing is basedon the mold parameters. At the end of the curing time, the mold parts805 and 810 are opened (or separated) at 1024 as described above withrespect to FIGS. 8C and 8D. As the mold engagement plate 315 is pulledaway, the force provided by the springs 815 helps to separate theinjection molding nozzle 775 from the formed part 825 (see FIG. 8D).When the mold engagement plate 315 has returned to its retractedposition, then the doors 110 can be released at 1027 to allow access tothe mold parts 805 and 810 and the molded part 825.

Although the flow diagram of FIG. 10 shows a specific order ofexecution, it is understood that the order of execution may differ fromthat which is depicted. For example, the order of execution of two ormore blocks may be scrambled relative to the order shown. Also, two ormore blocks shown in succession in FIG. 10 may be executed concurrentlyor with partial concurrence. Further, in some embodiments, one or moreof the blocks shown in FIG. 10 may be skipped or omitted. In addition,any number of counters, state variables, warning semaphores, or messagesmight be added to the logical flow described herein, for purposes ofenhanced utility, accounting, performance measurement, or providingtroubleshooting aids, etc. It is understood that all such variations arewithin the scope of the present disclosure.

Aspects of the present disclosure include, but are not limited to, areaction injection molding machine comprising: a housing comprising aninterior portion and exterior portion; at least one reactant materialstank engagement station in operational engagement with at least onereactant material tank comprising part A of an injection molding processand at least one reactant material tank comprising part B of theinjection molding process, wherein the reactant materials tanks areeach, independently, configured to sealingly engage with a correspondingengagement port in operational communication with the at least oneengagement station, thereby providing a first reactant materials fluidstream and a second reactant materials fluid stream, wherein each of thereactant materials tanks are configured to hold up to about threegallons each of reactant material, and wherein the reactant materialtanks are sized to fit substantially within at least some of the housingof the reaction injection molding machine; a molding support frameworkcomprising a first and a second mold support plate, wherein: the firstand second mold support plates are in respective operational engagementwith first and second mold engagement plates; and the first engagementplate is configured to securably engage with a first mold part, and thesecond engagement plate is configured to securably engage with a secondmold part to provide an assembled mold suitable for injection moldingwhen the two mold parts are sealingly engaged; an injection moldingmanifold in operational engagement with each of the first and secondreactant material fluid streams; and an injection molding nozzleengagement station configurable for operational engagement of a proximalend of a mixing nozzle with the injection molding manifold and a distalend of the mixing nozzle with the assembled mold.

Another aspect of the present disclosure includes, but is not limitedto, a mold for use in a reaction injection molding machine comprising: afirst mold part securable to a first mold part engagement plate; asecond mold part securable to a second mold part engagement plate,wherein the first and second mold parts are configured to provide a moldfor an injection molding process when the first and second mold partsare sealingly assembled, and wherein: either the first or second moldparts incorporate a mixing nozzle insertion point disposed through asurface of the assembled mold part; and either or both of the first orsecond mold parts incorporates an identification code that istransmittable to a mold identification signal receiver associated withthe reaction injection molding machine. The reaction injection moldingmachine can be configured to not engage in an injection moldingoperation when the first or second mold parts to not transmit anidentification signal that matches a mold authorization code.

Another aspect of the present disclosure includes, but is not limitedto, a reactant materials tank for use in a reaction injection moldingmachine comprising: a housing having an interior and an exterior,wherein the housing: is formed a material that is substantiallyimpervious to reactant materials used in a reaction injection moldingprocess; is configured to sealingly engage with an engagement station ofthe reaction injection molding machine; and is configured to provide aholding capacity of up to about 3 gallons of either the first or secondreactant materials.

Another aspect of the present disclosure includes, but is not limitedto, a reactant materials tank for use in a reaction injection moldingmachine comprising: a housing having an interior and an exterior,wherein the housing: is formed a material that is substantiallyimpervious to reactant materials used in a reaction injection moldingprocess; and is configured to: incorporate information about the originand status the tank and to transmit an authorization signal when thetank has been authorized for use; sealingly engage with an engagementstation of the reaction injection molding machine; and not to operatewhen the reactant materials tank does not transmit an authorization whenthe tank is engaged in the engagement station.

Another aspect of the present disclosure includes, but is not limitedto, a method of disengaging a fabricated mold part from a used injectionmolding nozzle comprising: providing a mixing nozzle comprisingpartially cured injection molding resin incorporated therein; providinga mold part at least partially connected to a distal end of the mixingnozzle via a sprue, wherein: the mold part is engaged with a moldsupport plate exterior surface; and the mold support plate is inoperational engagement with at least one spring that is secured to amold support plate interior surface; and applying a force to the spring,thereby generating a spring force suitable to sever the sprue, therebyseparating the fabricated mold part from the mixing nozzle.

As described above, the exemplary embodiments have been described andillustrated in the drawings and the specification. The exemplaryembodiments were chosen and described in order to explain certainprinciples of the disclosure and their practical application, to therebyenable others skilled in the art to make and utilize various exemplaryembodiments of the present disclosure, as well as various alternativesand modifications thereof. As is evident from the foregoing description,certain aspects of the present disclosure are not limited by theparticular details of the examples illustrated herein, and it istherefore contemplated that other modifications and applications, orequivalents thereof, will occur to those skilled in the art. Manychanges, modifications, variations and other uses and applications ofthe present construction will, however, become apparent to those skilledin the art after considering the specification and the accompanyingdrawings. All such changes, modifications, variations and other uses andapplications which do not depart from the spirit and scope of thedisclosure are deemed to be covered by the disclosure which is limitedonly by the claims which follow.

Therefore, at least the following is claimed:
 1. A reaction injectionmolding machine comprising: a. a housing comprising an interior portionand an exterior portion; b. at least one reactant materials tankengagement station in operational engagement with a first reactantmaterial tank comprising part A of an injection molding process and asecond reactant material tank comprising part B of the injection moldingprocess, wherein the first and second reactant material tanks are each,independently, configured to sealingly engage with a correspondingengagement port in operational communication with the at least onereactant materials tank engagement station, thereby providing a firstreactant material fluid stream and a second reactant material fluidstream, wherein each of the first and second reactant material tanks areconfigured to hold up to about three gallons each of reactant material,and wherein the first and second reactant material tanks are sized tofit substantially within at least some of the housing of the reactioninjection molding machine; c. a molding support framework comprising afirst mold support plate and a second mold support plate, wherein: i.the first and second mold support plates are in respective operationalengagement with first and second mold engagement plates; ii. the firstmold engagement plate is configured to securably engage with a firstmold part, and the second mold engagement plate is configured tosecurably engage with a second mold part to provide an assembled moldsuitable for injection molding when the first and second mold parts aresealingly engaged; and iii. the molding support framework:
 1. isconfigured to move the second mold engagement plate to clamp the secondmold part against the first mold part, thereby forming the assembledmold; and
 2. comprises a spring release assembly configured to applyforce to the first mold engagement plate opposite the first mold part,where the applied force facilitates disengagement of a distal end of amixing nozzle from the assembled mold; d. an injection molding manifoldin operational engagement with each of the first and second reactantmaterial fluid streams; and e. an injection molding nozzle engagementstation configurable for operational engagement of a proximal end of themixing nozzle with the injection molding manifold and the distal end ofthe mixing nozzle with the assembled mold.
 2. The reaction injectionmolding machine of claim 1, a configured to apply a pressure to theassembled mold during the injection molding process that does not exceedabout 500 psi.
 3. The reaction injection molding machine of claim 1,wherein the first and second reactant material tanks each,independently, comprise a reactant material to generate at least onethermoset plastic article or part from the injection molding process. 4.The reaction injection molding machine of claim 1, wherein the springrelease assembly comprises a plurality of springs operationally engagedwith the first mold engagement plate and the first mold support plate.5. The reaction injection molding machine of claim 1, wherein the mixingnozzle extends through the first mold engagement plate and the firstmold support plate for operational engagement of the distal end of themixing nozzle with the assembled mold.
 6. The reaction injection moldingmachine of claim 1, wherein the molding support framework comprises alinear drive system configured to move the second mold engagement plateto clamp the second mold part against the first mold part.
 7. Thereaction injection molding machine of claim 6, wherein the linear drivesystem comprises a plurality of motor driven lead screws supportedbetween the first and second mold support plates, the plurality of leadscrews in threaded engagement with the second mold engagement plate. 8.The reaction injection molding machine of claim 1, wherein the at leastone reactant materials tank engagement station comprises a pumpconfigured to provide at least the first reactant material fluid streamto the injection molding manifold.
 9. The reaction injection moldingmachine of claim 1, wherein at least one mold part of the first andsecond mold parts incorporates a mold identification that istransmittable to an identification signal receiver associated with thereaction injection molding machine.
 10. The reaction injection moldingmachine of claim 9, wherein the mold identification comprises aradio-frequency identification (RFID) tag incorporated into the at leastone mold part, the RFID tag configured to transmit an identificationsignal associated with the mold identification for the at least one moldpart.
 11. The reaction injection molding machine of claim 1, wherein thefirst and second reactant material tanks incorporate tankidentifications that are transmittable to an identification signalreceiver associated with the reaction injection molding machine.
 12. Thereaction injection molding machine of claim 11, wherein the tankidentifications comprise radio-frequency identification (RFID) tagsincorporated into the first and second reactant material tanks, the RFIDtags configured to transmit an identification signal associated with thetank identification, the tank identification corresponding to thereactant material in that reactant material tank.
 13. The reactioninjection molding machine of claim 11, wherein provision of the firstreactant material fluid stream and the second reactant material fluidstream is restricted until the tank identifications have been verifiedby the reaction injection molding machine.
 14. The reaction injectionmolding machine of claim 1, wherein the corresponding engagement portscomprise a check valve configured to provide a substantially leak proofseal between the first or second reactant material tank engaged withthat corresponding engagement port and the at least one reactantmaterials tank engagement station.
 15. The reaction injection moldingmachine of claim 13, wherein a spring loaded latch mechanism securelyengages the first or second reactant material tank with thecorresponding engagement port.
 16. The reaction injection moldingmachine of claim 1, wherein the first and second reactant material tankscomprise a fill level indicator configured to provide an indication ofreactant material in that reactant material tank.
 17. The reactioninjection molding machine of claim 16, wherein the fill level indicatorcomprises a magnetic float incorporated into that reactant materialtank.
 18. The reaction injection molding machine of claim 1, wherein thepart A is a catalyst material and the part B is a polyurethane reactantmaterial or a coreactive silicon or epoxy material.
 19. The reactioninjection molding machine of claim 18, wherein the catalyst material isa formulated polymeric isocyanate catalyst and the polyurethane reactantmaterial is a formulated polyol blend.
 20. The reaction injectionmolding machine of claim 1, wherein the first and second mold parts aregenerated using a 3D printing process.
 21. The reaction injectionmolding machine of claim 1, wherein the at least one reactant materialstank engagement station comprises a key-way for each correspondingengagement port, the key-way comprising features configured to alignwith corresponding features of either the first or second reactantmaterial tank containing the appropriate first or second reactantmaterial for that corresponding engagement port.